Orbiting Spray Head for Coating Complex Parts
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Solution Overview
Problem
Existing robotic systems face limitations when coating large, heavy, or geometrically complex parts, such as T-shaped aircraft landing gear, requiring expensive large robotic arms for full rotation and causing stress on rotating couplings in the coating pipe.
Innovation Solution
A method for controlling a robotic system with an articulated arm and a spray head that moves along a trajectory around the part axis, orienting the nozzle to maintain consistent material projection without needing extensive arm rotation, using a flexible pipe that reduces torsional stress and improves material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large robotic arms are used to enable full rotation of T-shaped parts, then complete coating coverage is achieved, but system cost and device complexity increase significantly
Solution Approach 1:
Instead of rotating the part in front of a stationary robot, the invention inverts the approach by keeping the part stationary and moving the robot around the part. This allows complete coating coverage to be achieved with a smaller, more cost-effective robotic system that orbits the workpiece rather than requiring the workpiece to be rotated before a large fixed robot.
Solution Approach 2:
The invention transitions from a two-dimensional approach (part rotation in front of robot) to a three-dimensional approach (robot orbiting the part along a circular trajectory around the part axis). This dimensional change enables complete coating coverage while using a smaller robotic arm, as the robot accesses all surfaces by moving around the part in three-dimensional space.
2Manufacturing precision
If the robotic arm rotates extensively to coat all surfaces, then complete coverage is achieved, but stress on rotating couplings and pipe increases, reducing system reliability
Solution Approach 1:
The invention reverses the traditional approach by keeping the part stationary and moving the robot around it. This eliminates extensive rotation of the part and its associated piping, thereby reducing stress on rotating couplings and improving system reliability while still achieving complete coating coverage.
Solution Approach 2:
The invention extracts the rotation function from the part and applies it to the robot instead. By moving the rotational movement to the robotic system orbiting the stationary part, the design eliminates the need for rotating couplings and pipes on the part itself, thereby improving reliability and reducing maintenance requirements.
3Manufacturing precision
If the part is rotated for coating, then complete surface coverage is achieved, but the part geometry and weight create operational difficulties
Solution Approach 1:
The invention inverts the operational approach by keeping the heavy or geometrically complex part stationary and moving the robot around it. This eliminates the operational difficulties associated with rotating large, heavy, or oddly shaped parts, while still achieving complete coating coverage through the robot's orbital motion around the part axis.
4Adaptability or versatility
If flexible pipe is used to supply material to the spray head, then adaptability to robot movement is improved, but torsional stress accumulates during extensive arm rotation
Solution Approach 1:
The invention reverses the movement pattern by keeping the part stationary and orbiting the robot around it. This minimizes the rotational movement of the robotic arm and associated piping, thereby reducing torsional stress on the flexible pipe while maintaining the adaptability needed for the robot's orbital trajectory around the part.
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
Enables efficient annular coating of parts with reduced arm movement and extended pipe lifespan, eliminating the need for costly large robotic arms and minimizing pipe torsion, thus improving maintenance and coating quality.
Implementation Method 1
a spray head provided with a nozzle for spraying the coating material
Data Source
Figure 1
Figure 2a~2d'
AI summary
Method for controlling an automated system (S) for applying a coating to a component (Pi), this automated system (S) comprising an articulated robot arm (1) and a spray head (T) provided with a spray nozzle (3), the method involving generating a command such: - that the spray head (T) is moved in a path (C) around a component (Pi) axis (B); and - that, along the entire path the nozzle (3) is oriented toward the component (Pi); and - that over a first portion (C1) of the path (C), a first side (K1) of the head is oriented toward a plane in which the component (Pi) is held; and - that over a second portion (C2) of the path (C1) a second side (K2) of the head (T) is oriented in the direction of said plane (P).