Remote Spray Foam System Reduces Worker Exposure
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Solution Overview
Problem
Workers applying spray polyurethane foam (SPF) chemicals often require extensive Personal Protective Equipment (PPE) due to the potential for hazardous airborne concentrations, even with effective engineering controls.
Innovation Solution
A remote spray foam system comprising a mast, a robot platform, a remote manipulator, a hand-held spray gun, and a control system that allows for the remote operation of the spray gun, minimizing the need for direct personnel exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If manual spray foam application is used, then application flexibility and control are maintained, but worker exposure to hazardous chemicals increases requiring extensive PPE
Solution Approach 1:
A robotic manipulator serves as an intermediary between the operator and the spray foam application process. The robot executes喷涂 operations while the operator controls it remotely, eliminating direct exposure to isocyanates and other hazardous chemicals. The system includes a robotic arm with spray gun, control system, and safety features that enable remote operation without compromising application quality
Solution Approach 2:
The patent replaces manual mechanical spray operations with an automated robotic system. The robotic manipulator uses computer-controlled movement and automated spray gun operation to perform insulation application, substituting human mechanical action with programmable robotic motion while maintaining precise control over foam application
2Reliability
If remote robotic operation is used, then worker safety is improved reducing PPE requirements, but system complexity and initial cost increase
Solution Approach 1:
The robotic system acts as a mediator that protects workers by performing hazardous tasks remotely. The system includes a robotic manipulator with integrated spray gun, control computer, and safety monitoring that enables operation from a safe distance while ensuring consistent, reliable application
Solution Approach 2:
The robotic system is designed to be self-contained with integrated foam mixing, heating, and spray delivery mechanisms. The robot autonomously navigates and positions the spray gun while the control system manages all operational parameters, reducing the need for extensive external support equipment and personnel
3Manufacturing precision
If traditional spray equipment is used, then equipment simplicity is maintained, but application precision and consistency deteriorate
Solution Approach 1:
The patent replaces manual spray equipment with a computer-controlled robotic system that uses sensors, programmable motion control, and automated spray gun manipulation to achieve precise foam application. The system maintains consistent spray patterns, coverage, and thickness through digital control rather than manual skill
Solution Approach 2:
The robotic spray system incorporates feedback mechanisms including sensors that monitor spray pattern, foam flow rate, and application thickness. The control system continuously adjusts operational parameters based on real-time data to maintain precision and consistency throughout the application process
Data Source
AI summary
A remote spray foam system includes a mast; a robot platform mounted to the mast; a remote manipulator mounted to the robot platform; a hand-held spray gun operable to spray foam, the hand-held spray gun removably mountable to the remote manipulator; and a control system operable to position the mast, and the remote manipulator to position and operate the spray gun.