Robotic Lifting and Orienting System for Overspray-Free Painting

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Solution Overview

Problem

Current vehicle paint systems face limitations in achieving overspray-free painting, particularly for complex vehicle surfaces, as existing systems are often restricted to decorative applications and struggle with horizontal or near-horizontal positioning, limiting their ability to paint entire vehicle bodies efficiently.

Innovation Solution

A robotic lifting and orienting system with automated carriers and manipulators that provide six degrees-of-freedom movement, allowing for precise positioning and orientation of vehicle components relative to paint robots, enabling efficient overspray-free painting of entire vehicle bodies by maintaining surfaces horizontal and perpendicular to the paint applicator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional conveyor-based paint systems are used, then painting capability is limited to decorative applications, but the system cannot achieve horizontal positioning for entire vehicle body painting

Engineering Contradiction:

Improvepainting capabilityVSAvoidhorizontal positioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The fixture is transformed from a static conveyor-based system to a dynamic robotic lifting and orienting system with six degrees-of-freedom manipulators that can actively adjust position and orientation in real-time, enabling horizontal positioning for entire vehicle body painting

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The traditional mechanical conveyor system is replaced with a robotic system using automated manipulators and actuators that provide precise control over fixture positioning and orientation, achieving superior horizontal positioning accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of energy

If conventional paint systems are used, then the system structure is simple, but overspray cannot be eliminated and transfer efficiency is low

Engineering Contradiction:

Improvetransfer efficiencyVSAvoidsystem structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The paint system is segmented into independent functional modules: robotic lifting and orienting system, paint applicator, and overspray management system. This modular approach enables high transfer efficiency through precise control while managing complexity through systematic decomposition

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the orientation parameter of the fixture to maintain horizontal surfaces during painting, and controls the position parameters to optimize spray angle and distance, achieving overspray-free painting with high transfer efficiency

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If fixed-position paint robots are used, then the system is easy to operate, but access angles to complex surfaces are limited

Engineering Contradiction:

Improvesystem operationVSAvoidaccess angles to surfaces

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The system replaces fixed-position robots with dynamic robotic manipulators that can adjust position and orientation in six degrees of freedom, providing optimal access angles to complex vehicle surfaces while maintaining ease of operation through automated control

Inventive Principle:

Principle #15Dynamics

4Manufacturing precision

If manual fixture positioning is used, then the system complexity is low, but painting precision and orientation control are insufficient

Engineering Contradiction:

Improvepainting precisionVSAvoidfixture positioning system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Manual fixture positioning is replaced with an automated robotic system using actuators and manipulators that provide precise control over position and orientation, achieving superior painting precision through automated mechanical systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates control modules that monitor and adjust manipulator positions in real-time, providing feedback control to maintain precise horizontal orientation and positioning accuracy throughout the painting process

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12042925B2Overspray-free paint system including AGV/AMR-based fixture lifting, positioining and orienting

Publication Date: 2024.07.23 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A robotic lifting and orienting system for an overspray-free paint system includes: a base coupled to wheels; and an automated carrier coupled to the base. The automated carrier includes: a fixture assembly configured to hold an object to be painted; one or more manipulators configured to move the fixture assembly relative to a paint robot; a propulsion system connected to the wheels and configured to move the robotic lifting and orienting system; and a control module configured to control the one or more manipulators and the propulsion system to control positioning and orienting of the object relative to at least one of the paint robot and an overspray-free paint applicator of the paint robot.