Robot Coating Path Programming via Digital Surface Copying
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Solution Overview
Problem
The existing methods for programming robots to apply coatings to inaccessible areas, such as flanged folds on vehicle doors, are laborious and time-consuming due to the need for iterative trial-and-error processes, resulting in potential collisions and suboptimal optical appearance.
Innovation Solution
A teaching framework allows for the disassembly and removal of components from the work piece, enabling precise and efficient on-line or off-line programming of the robot's application path, with tools like tolerance compensation devices and adjustable frameworks ensuring accurate positioning and optimization of application parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iterative trial-and-error programming is used to program robot application paths for inaccessible areas, then the robot can eventually achieve satisfactory coating application, but the programming process becomes extremely labor-intensive and time-consuming
Solution Approach 1:
The patent uses a camera to capture images of the work piece surface and creates a digital model (copy) of the surface geometry. This digital model is then used to plan and simulate the robot application path before actual execution, eliminating the need for repeated trial-and-error programming. The camera system captures the actual surface features including inaccessible areas, and the processed image data provides a virtual representation that can be analyzed and programmed without physical trial applications.
Solution Approach 2:
The patent performs preliminary measurement and modeling of the work piece surface before robot programming. By capturing images and creating a digital model in advance, the application path can be planned and optimized beforehand. This preliminary action includes analyzing the surface geometry, identifying target areas, and calculating the optimal robot trajectory, all before the actual coating process begins, thereby avoiding iterative adjustments.
2Ease of operation
If off-line programming on an independent computer is used to generate robot movement paths, then programming becomes simpler, but tolerance chain additions result in large cumulative tolerances that compromise application precision and may cause collisions
Solution Approach 1:
The patent creates a digital model (copy) of the actual work piece surface through camera imaging and image processing. This digital replica accurately represents the real geometry including all tolerances and surface features. The robot path is planned based on this accurate digital model, ensuring that the programmed path accounts for actual tolerances without adding cumulative tolerance errors from multiple measurement and programming stages.
Solution Approach 2:
The patent replaces traditional mechanical measurement systems with an optical measurement system using a camera. This substitution allows for non-contact, high-precision capture of surface geometry without the tolerance accumulation inherent in mechanical measurement chains. The image processing system converts optical data into precise digital coordinates that directly guide the robot, eliminating mechanical tolerance additions.
3Reliability
If the component is kept installed in the enclosure during programming, then the actual working conditions are maintained, but the programmer cannot see the exact position of the application nozzle relative to the surface area to be coated
Solution Approach 1:
The patent replaces direct visual inspection with an optical measurement system consisting of a camera and image processing unit. The camera captures images of the work piece surface and the application nozzle position, and the image processing system calculates the precise relative position from these images. This allows the programmer to see and measure positions accurately even when the component remains installed in the enclosure, maintaining working condition accuracy while solving the visibility problem.
Solution Approach 2:
The patent introduces an intermediary measurement system (camera and image processing) between the programmer and the actual work piece. This intermediary captures and processes visual information, converting it into usable data about nozzle position and surface geometry. The intermediary enables indirect observation and measurement, allowing the programmer to obtain precise position information without direct line-of-sight access to inaccessible areas.
Data Source
AI summary
In order to program the sealing membranes to be applied to attachment parts of vehicle bodies, for example to the edge-formed seam of vehicle doors using a robot, an attachment part may be removed from the body and, away from the latter, be mounted on a teach frame where all regions of the attachment part which need to be coated are highly visible to the programmer during programming.