Robotic Media Blasting With Pre-Scanned Tool Paths
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Solution Overview
Problem
Existing media blasting processes lack efficiency and precision in removing coatings from workpieces, often requiring real-time adjustments that can damage the substrate and are not well-suited for autonomous operation.
Innovation Solution
An autonomous media blasting system that utilizes a robotic arm with a blast nozzle, optical sensors, and actuators to create a virtual model of the workpiece, apply predefined blast parameters, and navigate the nozzle along a tool path to achieve a target scope of coating removal, adjusting parameters based on pre-scanned data rather than real-time feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If real-time adjustments are made during media blasting to improve coating removal efficiency, then productivity increases, but the substrate may be damaged due to excessive energy input
Solution Approach 1:
The system performs preliminary scanning of the workpiece to create a virtual model before blasting begins. Blast parameters and tool paths are pre-calculated based on the scanned geometry, allowing the system to execute predefined removal patterns without real-time adjustments that could cause substrate damage.
Solution Approach 2:
The system creates a virtual copy (digital model) of the workpiece through optical scanning. This virtual model is used to plan and simulate the blasting process, allowing parameter optimization and tool path generation without physically interacting with the actual workpiece, thereby preventing damage.
2Manufacturing precision
If traditional media blasting methods are used to achieve complete coating removal, then manufacturing precision improves, but the process complexity increases due to manual real-time monitoring and adjustment
Solution Approach 1:
The system replaces manual mechanical operations with automated robotic blasting. The robotic arm executes pre-calculated tool paths with high precision, eliminating the need for manual real-time monitoring and adjustment while maintaining or improving coating removal precision.
Solution Approach 2:
The system automatically adjusts blast parameters (pressure, flow rate, nozzle distance) based on pre-scanned workpiece geometry and material properties. These parameters are optimized beforehand and dynamically controlled by the system without requiring manual intervention, reducing process complexity while maintaining precision.
3Ease of operation
If autonomous operation is implemented without real-time feedback to reduce device complexity, then ease of operation improves, but adaptability to varying workpiece geometries deteriorates
Solution Approach 1:
The system performs preliminary scanning and virtual modeling of each unique workpiece before processing. This advance preparation allows the autonomous system to adapt to specific geometries through pre-calculated tool paths and parameters, eliminating the need for real-time feedback while maintaining versatility.
Solution Approach 2:
The system applies localized blast parameters and tool paths tailored to specific regions of the workpiece based on the scanned geometry. Different areas receive customized processing parameters appropriate to their specific geometric characteristics, enabling autonomous adaptation without real-time monitoring.
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
Enables precise and efficient coating removal across the entire workpiece without real-time data adjustments, preventing substrate damage and ensuring consistent results through predefined parameters and tool paths.
Implementation Method 1
accessing a plurality of images captured by an optical sensor traversing a scan path over the workpiece
Implementation Method 2
via a set of actuators, navigating an end effector along a tool path
Implementation Method 3
projecting blasting media toward the workpiece according to a set of blast parameters
Implementation Method 4
media blasting a workpiece... detecting a scope of coating removal from a first test location
Data Source
AI summary
A method for media blasting a workpiece includes, during a scan cycle: accessing a first set of images captured by an optical sensor traversing a scan path over the workpiece; compiling the first set of images into a virtual model of the workpiece; accessing a first set of blast parameters; generating a first tool path for a first workpiece region of the workpiece based on a geometry of the workpiece represented in the virtual model and the first set of blast parameters. The method further includes, during a processing cycle: via the set of actuators, navigating the blast nozzle over the first workpiece region according to the first tool path; and projecting blasting media toward the workpiece according to the first set of blast parameters.