Paint Spraying Parameter Adaptation via Spray Pattern Matching

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Solution Overview

Problem

The increasing complexity of parts to be painted, variety of colors, and shorter product cycles in paint-spraying plants require more demanding setup of paint-spraying control systems, especially with the adoption of robot technology, which is resource-intensive for adapting to new paints or components.

Innovation Solution

A method for determining spraying parameters for a paint-spraying apparatus that adjusts known parameters based on the characteristics of a new spraying agent, such as solid content, viscosity, or surface tension, to achieve a similar spray pattern without mechanical conversion, using nested iteration loops for air current adjustments and simulation to maintain consistent coating quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If robot technology is used for paint-spraying plants, then the demands upon operators are met and coating quality is improved, but the effort in setting up control systems for new paints and components increases significantly

Engineering Contradiction:

Improvecoating qualityVSAvoidsetup effort for control systems

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention automatically adapts spraying parameters (air currents, paint quantity, atomizer rotation speed) by detecting changes in spraying agent characteristics (viscosity, solid content, surface tension) and adjusting parameters through simulation and iteration, eliminating manual recalibration while maintaining coating quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The control system performs self-adjustment by automatically detecting new spraying agent properties and recalculating optimal parameters without operator intervention, using nested iteration loops to adapt air currents and other parameters based on simulated spray pattern comparisons

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If spraying parameters are manually adjusted for new spraying agents, then coating quality can be maintained, but time and computing effort are significantly consumed

Engineering Contradiction:

Improvecoating thickness distributionVSAvoidparameter adjustment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system pre-calculates and stores optimal spraying parameters for various spraying agent characteristics in a database, allowing rapid retrieval and adaptation without time-consuming manual adjustments or extensive real-time computing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses iterative simulation comparing calculated spray patterns with reference spray patterns, automatically adjusting parameters based on deviation analysis until similarity criteria are met, reducing both time and computing effort through efficient feedback loops

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If mechanical conversion is performed to adapt to new spraying agents, then spraying performance can be optimized, but device complexity and conversion effort increase

Engineering Contradiction:

Improvespraying performance adaptationVSAvoidmechanical conversion requirement

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention replaces mechanical conversion with automated parameter adjustment and simulation-based adaptation, using software control to modify spraying behavior instead of physical modifications to the spray apparatus

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control system is designed to handle multiple spraying agent types universally through automatic detection and adaptation of parameters, eliminating the need for mechanical conversions while maintaining optimized spraying performance across different materials

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8551573B2Method for determining spraying parameters for controlling a paint-spraying apparatus using a spraying agent

Publication Date: 2013.10.08 ABB AG(DE)

AI summary

A method for determining spraying parameters for controlling a paint-spraying apparatus using a spraying agent is disclosed. A known spray pattern is provided which has been determined by means of known spraying parameters for the use of a first spraying agent. A provisional spray pattern is calculated using the known spraying parameters and the characteristics of a second spraying agent. The known spraying parameters are altered in order to acquire changed spraying parameters which yield a further spray pattern. The changed spraying parameters are altered to the point where the further spray pattern is similar to the known spray pattern within a similarity criterion. The changed spraying parameters corresponding to the further spray pattern are intended as spraying parameters for the second spraying agent and are provided to the paint-spraying apparatus whenever the second spraying agent is used. The spraying parameters comprise a plurality of air currents which influence the spraying behavior of the paint-spraying apparatus.