Robot-Mounted UV Lamp Assembly for Vehicle Panel Coverage
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Solution Overview
Problem
Existing methods for curing vehicle panel paint, such as using cure ovens or stationary UV lamps, are energy-intensive and inefficient, often leaving uncured portions due to poor line of sight issues.
Innovation Solution
A robotic system equipped with a UV light-emitting lamp assembly mounted on a robot arm, capable of maneuvering to ensure complete curing of vehicle panels using UV-A, UV-B, and UV-C lights, with adjustable intensity and duration, and an end effector for panel movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stationary UV lamps or cure ovens are used to cure paint, then complete curing coverage can be achieved, but energy consumption increases and curing time is extended
Solution Approach 1:
The patent applies the dynamics principle by transitioning from stationary UV lamps to a mobile robotic system. The robot arm with mounted UV lights can dynamically position itself around the vehicle panel, maintaining optimal distances and angles for curing. This mobility allows concentrated energy delivery to specific areas rather than illuminating entire spaces, reducing overall energy consumption while ensuring complete coverage through systematic movement patterns.
Solution Approach 2:
The patent replaces the thermal-mechanical curing system (cure ovens that heat entire chambers) with a targeted optical system (UV LEDs mounted on robots). This substitution eliminates the need to heat large volumes of air and only applies energy directly to the paint surface where curing is needed, dramatically reducing energy consumption while maintaining curing effectiveness.
2Reliability
If stationary UV lamps are used to cure paint, then curing can be performed, but line of sight issues result in uncured portions
Solution Approach 1:
The robotic system dynamically repositions UV light sources around the vehicle panel from multiple angles and distances. The robot arm can extend, retract, and rotate to illuminate previously shadowed areas, ensuring complete coverage without the line-of-sight limitations of stationary lamps. This dynamic positioning allows the system to adapt to complex panel geometries and achieve uniform curing across all surfaces.
Solution Approach 2:
The patent introduces multi-dimensional movement capabilities to the curing system. Instead of fixed-position lamps, the robotic system operates in three-dimensional space, moving along multiple axes to approach the panel from various angles. This dimensional freedom allows UV lights to reach obscured surfaces and crevices that stationary lamps cannot access, eliminating uncured portions.
3Reliability
If cure ovens are used to cure paint, then complete curing can be achieved, but processing time is extended
Solution Approach 1:
The patent replaces thermal curing (which requires prolonged exposure to heat cured paint throughout the entire panel and surrounding air) with direct UV photopolymerization. The UV LEDs emit specific wavelengths that immediately trigger the curing reaction in UV-curable paints, reducing processing time from minutes or hours to seconds while ensuring complete curing through targeted energy delivery.
Solution Approach 2:
The robotic system performs curing in continuous passes, moving systematically across the panel surface without interruption. The robot arm maintains optimal positioning and continuously delivers UV energy as it traverses the panel, eliminating the downtime and thermal equilibration periods required by cure ovens. This continuous action approach significantly reduces total curing time while maintaining complete coverage.
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
The robotic system efficiently cures paint on vehicle panels with reduced energy consumption and time, ensuring thorough coverage without leaving uncured areas.
Implementation Method 1
The lamp assembly is disposed at the second end of the robot arm and includes at least one ultraviolet (UV) light that is configured to cure paint on a panel of a vehicle
Implementation Method 2
at least one ultraviolet (UV) light that is configured to cure paint on a panel of a vehicle
Data Source
AI summary
A robotic system is provided. The robot system includes a robot arm, a lamp assembly, and a control module. The robot arm includes a first end and a second end that opposes the first end. The lamp assembly is disposed at the second end of the robot arm and includes at least one ultraviolet (UV) light that is configured to cure paint on a panel of a vehicle. The control module is configured to actuate the robot arm and position the lamp assembly relative to the panel of the vehicle.