Robotic Applicator Coating System with Laser Sensors
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Solution Overview
Problem
Current coating systems for glass substrates, particularly in automotive and building applications, face inefficiencies due to labor-intensive operations, inadequate coating application, and limited ability to customize coating profiles, leading to material waste and increased costs.
Innovation Solution
A robotic coating system equipped with a pumping and dispensing system, laser sensors for real-time monitoring and adjustment, and a control unit that allows for precise application of multiple coatings, including primers, solvents, and adhesives, with real-time modification capabilities based on substrate shape and position, enabling efficient and customizable coating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual or operator-controlled coating systems are used, then flexibility in operation is maintained, but labor intensity increases and coating precision decreases
Solution Approach 1:
The patent replaces manual mechanical coating operations with an automated robotic system that uses computer vision and real-time sensing. The robotic applicator with integrated laser sensors and cameras automates the coating process, eliminating manual labor while maintaining operational flexibility through programmable control and adaptive real-time modification of coating parameters.
Solution Approach 2:
The system incorporates self-correction capabilities through real-time optical monitoring and automated feedback control. The robotic applicator automatically adjusts coating parameters based on sensor data, performing self-verification and self-correction without human intervention, thereby improving precision while reducing labor intensity.
2Device complexity
If traditional spray nozzle systems are used, then coating application is simplified, but material waste increases due to inadequate control
Solution Approach 1:
The system implements real-time feedback control using optical sensors, laser scanners, and cameras that monitor coating application continuously. This feedback loop enables the robotic system to adjust coating parameters dynamically, ensuring precise material application and minimizing waste while maintaining controlled and consistent coating quality.
Solution Approach 2:
The robotic coating system dynamically adapts its operation in real-time based on sensor feedback. The system modifies coating speed, spray rate, and applicator position dynamically during the coating process, optimizing material usage and reducing waste while maintaining operational control.
3Device complexity
If fixed coating profiles are used, then system simplicity is maintained, but adaptability to different substrates decreases
Solution Approach 1:
The robotic coating system is designed with universal adaptability to handle multiple substrate types, shapes, and coating requirements through programmable control. The system can be configured for different coating profiles and parameters digitally, enabling it to adapt to various applications without physical reconfiguration, thus maintaining simplicity while achieving versatility.
Solution Approach 2:
The system performs preliminary scanning and substrate characterization using optical sensors and laser scanners before coating application. This preliminary action allows the system to pre-determine the optimal coating path and parameters for each specific substrate, enabling customization without increasing operational complexity during the actual coating process.
4Reliability
If operator-controlled inspection systems are used, then process control is maintained, but labor costs increase and error rates remain high
Solution Approach 1:
The patent replaces manual operator-controlled inspection systems with automated optical inspection systems using cameras, laser scanners, and sensors. This substitution eliminates human labor from the inspection process while providing continuous, objective monitoring and verification of coating quality, thereby improving reliability and reducing errors.
Solution Approach 2:
The inspection system performs self-verification by automatically comparing applied coatings against target specifications using optical sensing and pattern recognition. The system identifies and flags deviations automatically, providing self-correction capabilities that reduce human intervention and improve both reliability and productivity.
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 system reduces material waste, labor costs, and application errors by ensuring precise coating application and customization, optimizing the use of coatings and improving production efficiency.
Implementation Method 1
At least a first laser system and at least a second laser system mounted on each of the first applicator and the second applicator for observing the shape of the substrate and for monitoring the application of at least the first coating and the second coating onto the surface of the substrate
Data Source
AI summary
A robotic applicator and a coating system and method for real-time control of the application of one or more coatings onto the surface of a substrate. The coatings can include various primer layers, adhesive agents, tinting/coloring agents, and/or chemical solvent layers onto glass substrates. A single robotic applicator can include a pair of applicators to apply different coating layers onto the substrate surface. The overall system and method includes an initial optical vision system, along with a series of optical vision systems, and a series of robotic applicators, that cooperate with a central processing unit to customize the coating sequence and pattern for the particular substrate material, shape, and/or intended use of the coated substrate.