Robot Coating Control for Consistent Width and Thickness

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Solution Overview

Problem

Existing application systems for viscous materials face challenges in maintaining consistent quality of coating on workpieces due to variations in operating states and environmental conditions, leading to inconsistencies in application width and thickness.

Innovation Solution

An application system comprising an articulated robot and a control device that calculates and adjusts a control target value based on operating state information and target quality information, using an estimation model to ensure precise positioning and orientation of the discharge circuit, thereby stabilizing the application quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional application systems are used without real-time control adjustment, then the system structure remains simple, but the application quality becomes inconsistent due to variations in operating state and environmental conditions

Engineering Contradiction:

Improveapplication quality consistencyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The control device calculates a control target value based on operating state information (such as robot position, discharge circuit orientation, material viscosity) and target quality information, then adjusts the application parameters in real-time. This feedback mechanism ensures consistent application quality by compensating for variations in operating conditions without requiring complex hardware modifications

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts control parameters (discharge amount, discharge timing, robot speed, discharge circuit orientation) based on calculated target values that account for environmental conditions and material properties. This allows the system to maintain application quality consistency through parameter optimization rather than structural complexity

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the discharge circuit position and orientation are not precisely controlled, then the control system remains simple, but the application width and thickness become inconsistent

Engineering Contradiction:

Improveapplication width and thickness consistencyVSAvoiddischarge circuit positioning difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The control device calculates the optimal control target value before the application process begins, taking into account the workpiece shape, discharge circuit characteristics, and target application quality. This preliminary calculation enables precise positioning and orientation control during execution without requiring complex real-time manual adjustments

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces manual positioning operations with automated control based on calculated target values. The control device uses operating state information to automatically adjust the robot position and discharge circuit orientation, eliminating the need for complex mechanical positioning mechanisms and manual calibration

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20220193710A1Application system, control device, control method, and non-transitory computer-readable storage medium storing a program

Publication Date: 2022.06.23 YASKAWA DENKI KK

AI summary

An application system is provided, which includes an application device configured to discharge a coating material from a discharge circuit; an articulated robot configured to change a position and an orientation of the discharge circuit such that the coating material from the discharge circuit is applied to a workpiece; and a control device configured to control the application device and the articulated robot, in which the control device includes a target value calculation circuit and an operation control circuit.