Robot Coating System Pilot Pressure Control
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Solution Overview
Problem
Existing robot coating systems face challenges in maintaining a consistent coating amount of viscous materials when interrupted and resumed, leading to variations in sealing strength and increased cycle time due to the need for precise control over coating time and speed.
Innovation Solution
A robot coating system with a pilot pressure unit to set a predetermined pressure before coating, a coating executing unit for controlled flow rate and time, and a post-coating stopping unit to ensure the pump stops only after completing the coating task, along with an immediate stopping unit for immediate cessation and a selection unit to choose between stopping methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the robot stops temporarily at the target position for scatter coating, then the coating amount can be controlled, but the cycle time of the robot system increases
Solution Approach 1:
The pump is driven in advance before the robot reaches the target position to establish the required pilot pressure. This preliminary action ensures that when coating begins, the system is already in the correct state, eliminating the need for temporary stops and pressure re-establishment, thus reducing cycle time while maintaining coating precision
Solution Approach 2:
The coating process is designed to continue without interruption by maintaining pilot pressure throughout the movement to the target position. The pump operates continuously at appropriate speeds to ensure seamless transition from movement to coating, eliminating idle time and maintaining productive action throughout the cycle
2Reliability
If the coating gun stops when an alarm is issued, then the robot stops safely, but the coating work is interrupted and the coating amount varies
Solution Approach 1:
The pump is driven in advance before reaching the target position to establish the required pilot pressure. This preliminary action ensures that when coating begins, the system is already in the correct state, eliminating the need for temporary stops and pressure re-establishment, thus reducing cycle time while maintaining coating precision
Solution Approach 2:
The coating process is designed to continue without interruption by maintaining pilot pressure throughout the movement to the target position. The pump operates continuously at appropriate speeds to ensure seamless transition from movement to coating, eliminating idle time and maintaining productive action throughout the cycle
3Speed
If the pump stops immediately when a stop command is issued, then the coating work is halted quickly, but the coating amount may be insufficient
Solution Approach 1:
The control unit monitors the coating process and pump operation in real-time. When a stop command is issued, the system uses feedback to determine the appropriate moment to stop the pump - after the coating amount has been verified to be sufficient, ensuring both quick response and accurate coating completion
Solution Approach 2:
The pump speed is dynamically adjusted during operation to match the coating requirements. The system can quickly respond to stop commands by dynamically controlling pump acceleration and deceleration, allowing for both rapid stopping and precise coating amount control through dynamic speed modulation
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
Ensures consistent coating amounts across planned positions even after interruptions, preventing variations in sealing strength and reducing cycle time by allowing precise control over coating processes.
Implementation Method 1
a pump (13) which imparts a predetermined pilot pressure to the viscous material
Data Source
AI summary
A robot coating system (1) includes a robot moving unit (21) which makes a robot (11) having a coating gun (12) successively move to a plurality of planned coating positions, a readying pressure imparting unit (22) which drives a pump (13) of the coating gun before reaching the planned coating positions and imparts to the viscous material a predetermined readying pressure without coating the viscous material, a coating executing unit (23) which executes coating work of the viscous material by a predetermined flow rate over a predetermined coating time when the coating gun has reached a planned coating position, and a post-coating stopping unit (24) which continues the coating work to make the pump stop after the end of the work when executing the coating work and a stop command of the robot is issued.