Mobile Sprayer Navigation for Surface Transitions and Overspray Control

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Solution Overview

Problem

Existing automated painting systems require complex robotic arms with multiple joints and fixed bases, making them cumbersome and limiting their ability to efficiently coat components without overspray.

Innovation Solution

An automated mobile sprayer (AMS) with a mobile base, a spray module, distance and navigation sensors, and a control module that enables lateral movement and orientation adjustments based on sensor data to apply fluid efficiently and avoid overspray.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a robotic arm with multiple joints and fixed base is used, then the system can provide the degree of freedom necessary to coat components, but the system becomes complex and cumbersome

Engineering Contradiction:

Improvedegree of freedomVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent transforms the fixed robotic arm system into a mobile platform that can dynamically reposition itself. The automated mobile sprayer with lateral and longitudinal movement capabilities replaces the need for multiple fixed joints, providing adaptability through mobility rather than mechanical complexity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system separates the spraying function from the positioning function. The mobile base handles positioning while the spray module handles coating, allowing each component to be optimized independently rather than requiring a complex integrated robotic arm

Inventive Principle:

Principle #1Segmentation

2Productivity

If a fixed base robotic arm is used, then the system can coat components, but the system requires the component to move to a position where the arm can reach it

Engineering Contradiction:

Improvecoating efficiencyVSAvoidoperation convenience

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

Instead of moving the component to the robotic arm's reach, the patent inverts the approach by moving the robotic arm (now mobile sprayer) to the component's location. This eliminates the need for component handling and repositioning, greatly improving ease of operation

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If the spray fan is oriented orthogonal to the sweep direction, then the spray can be applied systematically, but overspray occurs on non-target surfaces

Engineering Contradiction:

Improvespray application efficiencyVSAvoidoverspray

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent implements local quality control by using multiple distance sensors positioned at different locations to detect surface features. The system adjusts spray orientation and positioning locally based on detected transitions and voids, applying coating only where needed while avoiding overspray on adjacent surfaces

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system uses real-time feedback from distance sensors to continuously adjust spray parameters. When transitions or voids are detected, the control module modifies spray orientation and positioning to prevent overspray, creating a closed-loop control system that eliminates harmful overspray effects

Inventive Principle:

Principle #23Feedback

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 AMS effectively coats surfaces by maintaining spacing and orientation, avoiding voids and adjusting to transitions, providing a smooth finish while reducing overspray.

Implementation Method 1

Fluid spray systems produce an atomized fluid spray fan and apply the spray fan to a surface

Methodology Applied

Scientific EffectAtomization:

Implementation Method 2

a plurality of distance sensors oriented longitudinally and configured to generate distance data

Methodology Applied

Scientific EffectTime of Flight: Time of Flight

Implementation Method 3

a mobile base having a lateral axis and a longitudinal axis; a spray module supported by the mobile base

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20250367696A1Automated mobile sprayer spraying and navigation

Publication Date: 2025.12.04 GRACO MINNESTOA INC

AI summary

An automated mobile sprayer (AMS) is configured to apply stripes of fluid to target surfaces to coat those target surfaces with the fluid. A control module of the AMS controls movement and spraying by the AMS. The control module causes the AMS to follow a target surface based on distance data from distance sensors configured to detect the target surface. Voids in the surface can be detected by the distance sensors. The control module can drive the AMS across the voids based on navigation data generated by navigation sensors of the AMS. The control module. The control module identifies transitions between the target surface and other surfaces based on the distance data. The control module is configured to identify and distinguish between various transition types based on the distance data. The control module controls movement and spraying by the AMS relative to the transition based on the transition type identified.