Robot End Effector Brush Coating with Camera Verification
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Solution Overview
Problem
Existing end effectors for robot arms, particularly those used for coating tasks, face challenges in applying coatings evenly to irregular surfaces without masking, as they often rely on spray methods that struggle with side surfaces due to electronic components and surface irregularities.
Innovation Solution
An end effector equipped with a camera, a support member, and a brush that captures the brush tip's image to ensure proper coating application, allowing for precise application on end portions and irregular surfaces without masking, using a brush to apply the coating agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a spray method is used for coating, then the coating process can be automated, but the coating uniformity on irregular surfaces deteriorates
Solution Approach 1:
The patent replaces the spray method with a brush-based mechanical coating system. The brush is driven by a vibration mechanism that enables it to conform to irregular surfaces, providing uniform coating application through direct mechanical contact rather than aerosol deposition. This substitution allows automation while maintaining coating quality on complex geometries.
Solution Approach 2:
The brush is equipped with a vibration mechanism that causes the brush tips to vibrate during coating application. This vibration enables the brush to adapt to surface irregularities, maintain consistent contact pressure, and distribute coating material uniformly across the workpiece surface, thereby achieving both automation and coating precision.
2Object-affected harmful factors
If masking is used to protect electronic components, then component protection is improved, but the device complexity increases
Solution Approach 1:
The brush system employs brushes with varying tip characteristics - some brushes have softer tips for delicate areas near electronic components, while others have firmer tips for robust surfaces. This local differentiation of brush properties allows selective coating application that automatically protects sensitive components without requiring additional masking structures or processes.
Solution Approach 2:
The vibration mechanism enables the brush to self-adjust to the workpiece surface topology, automatically conforming to irregularities and avoiding electronic components through real-time adaptation. This self-adjusting capability eliminates the need for pre-planned masking arrangements, reducing process complexity while maintaining component protection.
3Measurement precision
If the camera captures both brush tip and marker simultaneously, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The camera is positioned to simultaneously capture both the brush tip and the marker in a single field of view. This merged observation approach allows the control system to correlate brush position with reference marker position in real-time, achieving precise positioning and coating control without requiring multiple separate sensing systems or complex mechanical arrangements.
Data Source
AI summary
An end effector connectable to a robot arm includes a camera, a support member that includes a marker and supports a workpiece, and a brush that performs coating on the workpiece. The camera is arranged at a position allowing the camera to capture a brush tip of the brush and the marker simultaneously.