Robot Sealer Brushing With 3D Path Matching and Brush Renewal
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Solution Overview
Problem
Manual sealer application in vehicle manufacturing results in inconsistent quality due to human error, leading to musculoskeletal issues and inefficiencies.
Innovation Solution
A sealer work automation system using a robot equipped with a brushing work tool, 3D sensor, residual sealer remover, brush examiner, and tool replacer, which automates sealer application, residual sealer removal, and brush maintenance, utilizing magnetic tool changing and 3D data processing for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual brushing work is used to apply sealer to joints, then the worker can perform the task with simple equipment, but the sealer application quality becomes inconsistent and human error occurs
Solution Approach 1:
The system performs self-diagnosis through the 3D sensor to detect brush state automatically, and the brush is designed to be self-replenishing by storing sealer within its structure. This eliminates the need for manual quality inspection and maintains consistent application without complex external monitoring systems.
Solution Approach 2:
The brush is pre-loaded with sealer material before use, allowing it to function as a self-contained application device. The robot is pre-programmed with the optimal brushing path based on 3D scanned data, enabling consistent quality from the start of operation without requiring manual adjustment during work.
2Productivity
If manual brushing work is performed repeatedly while looking up, then the worker can complete the task, but musculoskeletal fatigue and injury occur
Solution Approach 1:
The manual mechanical brushing action is replaced with an automated robot system that executes precise movements based on 3D scanned data. The robot performs the repetitive brushing task without any musculoskeletal system, completely eliminating fatigue and injury risks while maintaining high productivity.
3Extent of automation
If a robot performs brushing work with a fixed brush, then automation is achieved, but the brush cannot adapt to varying joint geometries
Solution Approach 1:
The brush is designed with dynamic characteristics that allow it to adapt its shape and sealer flow to match the joint geometry being sealed. The robot controller dynamically adjusts brushing parameters based on real-time 3D sensor feedback, enabling the automated system to handle varying geometries effectively.
Solution Approach 2:
The 3D sensor continuously scans the joint geometry during operation and feeds this information back to the robot controller, which adjusts the brushing path and pressure in real-time. This closed-loop feedback system maintains adaptability to varying geometries while preserving full automation.
4Productivity
If the robot moves quickly to complete brushing work, then productivity increases, but the 3D scanning and path generation time may increase
Solution Approach 1:
The 3D scanning and path generation are performed as preliminary actions before the actual brushing operation begins. This allows the robot to execute the brushing task at full speed without real-time computational delays, as all planning is completed in advance based on the pre-acquired 3D model.
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 sealer application quality, reduces manual labor, and enhances operational efficiency by automating sealer removal and brush replacement processes.
Implementation Method 1
a 3D sensor mounted on the robot and photographing a work portion of the joint to acquire 3D data
Implementation Method 2
a main changer attached to the robot, and including a first magnet in a lower part and a sub changer mounted on or detached from the main changer by a wireless switching scheme using a second magnet configured in an upper part
Data Source
AI summary
An embodiment sealer work automation system includes a robot configured to perform a brushing work of spreading a sealer applied to a joint by moving a brushing work tool to a work location of an under body, a three-dimensional (3D) sensor mounted on the robot and configured to photograph a work portion of the joint to acquire 3D data, a residual sealer remover configured to remove a residual sealer by applying a physical force to a brush of the brushing work tool contaminated after the brushing work, a robot path generator configured to generate a robot path for the brushing work by matching the 3D data received from the 3D sensor and design data for the brushing work of the joint, and a robot controller configured to control an overall operation of the robot and to control the brushing work of the robot based on the robot path.