Reusable Master Path Rules for Robotic Coating Application
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Solution Overview
Problem
Current robotic painting methods require time-consuming and labor-intensive manual programming for each unique coating and surface, especially for large structures like aircraft, where different paint colors and material characteristics necessitate individualized application paths, making it economically infeasible to test multiple coatings on structures.
Innovation Solution
A system using reusable master path rules is developed, which generates a framework of points on a structure's surface, creates a universal master path for coating application, and applies coatings using a controller to streamline the process by reusing path rules and adjusting application parameters for different coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual programming is used for each unique coating and surface pairing, then coating application quality can be optimized for specific conditions, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The system creates a universal master path that can be reused across multiple coating applications on different surfaces. Instead of programming a unique path for each coating-surface pairing, the master path serves as a template that can be adapted and reused, eliminating redundant programming efforts while maintaining optimized coating application quality.
Solution Approach 2:
The master path is pre-programmed and stored for future use. By performing the path programming activity once in advance and storing it as a reusable template, the system eliminates the need to re-program similar paths repeatedly, significantly reducing programming time for subsequent coating operations.
2Manufacturing precision
If individualized application paths are created for each coating on large structures, then coating quality can be optimized for specific material characteristics, but the process becomes economically infeasible due to testing requirements
Solution Approach 1:
The master path serves as a universal template that can be applied to multiple different coatings and surfaces. This eliminates the need to create and test individualized paths for each coating-surface pairing, making the process economically feasible while still maintaining optimized coating quality through the reusable path.
Solution Approach 2:
The system creates a master path that can be copied and reused for multiple coating applications. Instead of creating unique paths for each coating, the same master path template is copied and adapted, eliminating the need for repeated testing and development while maintaining consistent coating quality.
3Productivity
If reusable master path rules are implemented, then programming time and labor are reduced, but the system complexity increases due to framework generation and path rule creation
Solution Approach 1:
The framework and master path rules are generated once in advance and stored for future use. Although the initial setup requires computational resources, the pre-generated templates can be quickly reused for multiple coating operations, resulting in net productivity gains that outweigh the initial system complexity.
Solution Approach 2:
The system replaces manual programming operations with automated computational processes. The framework generator and path rule creator use algorithms to automatically generate optimized paths based on surface data, eliminating the need for manual programming while reducing overall system complexity through automation.
4Productivity
If a universal master path is used for multiple surfaces, then programming effort is reduced, but the path may not be optimized for specific surface characteristics
Solution Approach 1:
The system allows the universal master path to be adapted with local modifications for specific surface characteristics. While the overall path structure remains universal for efficiency, local adjustments can be made to optimize the path for specific surface geometries and coating requirements, balancing reusability with precision.
Solution Approach 2:
The master path system is designed to be dynamic and adaptable rather than rigid. The path rules can be modified and adjusted based on specific surface characteristics while maintaining the overall universal structure, allowing the system to optimize for both productivity and manufacturing precision through flexible adaptation.
Data Source
AI summary
A method of applying a coating to at least a portion of a surface of a structure using reusable master path rules. The surface of the structure is identified to form surface data. A framework for the surface of the structure is generated using the surface data. The framework comprises a plurality of points. Reusable master path rules are created for a master path connecting the plurality of points. The master path is a continuous line representing a universal route for applying coatings to the surface. The coating is applied to the at least a portion of the surface of the structure using the reusable master path rules.