Robotic Surface Processing Paths for Curved Clear Coat Repair
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Solution Overview
Problem
Automating clear coat repair and other surface processing applications in the automotive industry is challenging due to the difficulty in handling curved surfaces and surface features, as existing robotic systems lack the ability to intuitively adjust trajectories and process parameters to accommodate complex topographies, leading to manual intervention and limited automation in paint repair processes.
Innovation Solution
A robotic system that includes a surface inspection system, a robotic arm with a surface engaging tool, and a process mapping system capable of approximating surface topography, generating a surface processing plan with trajectory modifications based on detected surface features, and producing control signals for the robotic arm to adjust force, velocity, and rotational speed profiles, allowing for automated defect repair on curved and feature-rich surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a robotic system uses a fixed trajectory for surface processing, then the control system is simple, but the system cannot adapt to curved surfaces and surface features
Solution Approach 1:
The system performs preliminary scanning of the worksurface to capture surface geometry data before processing. This advance knowledge allows the trajectory generation system to pre-calculate appropriate trajectory modifications for surface features, enabling adaptive processing without real-time complexity
Solution Approach 2:
The trajectory generation system dynamically adjusts processing trajectories based on detected surface features. The system transitions from static fixed trajectories to dynamic adaptive trajectories that respond to surface topography, curvature, and identified features during the processing operation
2Productivity
If manual intervention is used for clear coat repair, then the quality is high, but the productivity is low
Solution Approach 1:
The system incorporates feedback mechanisms where surface scanning data informs trajectory adjustments, and processing results are monitored to ensure quality standards are met. This closed-loop approach enables automated systems to maintain precision comparable to manual operations while achieving higher productivity
Solution Approach 2:
The robotic system performs self-adjustment based on detected surface features, automatically modifying trajectories and processing parameters without human intervention. The system serves itself by using its own sensing capabilities to guide its processing actions, maintaining quality while enabling full automation
3Manufacturing precision
If the robotic system processes complex surfaces with fixed parameters, then the device complexity is low, but the manufacturing precision deteriorates
Solution Approach 1:
The system applies different processing parameters and trajectory characteristics to different regions of the worksurface based on local surface features. Each area receives customized processing appropriate to its specific topography and features, achieving high precision without requiring the entire system to be maximally complex
Data Source
AI summary
A robotic system is presented that includes a surface inspection system that receives sampling information for a number of areas within a region of a worksurface. The system also includes a robotic arm, coupled to a surface engaging tool, the robotic repair arm being configured to cause the surface processing tool to engage the region of the worksurface. The system also includes a process mapping system configured to, based on the sampling information: approximate a surface topography in the region of the worksurface, generate a surface processing plan for the region based on the approximated surface topography that includes a trajectory. The surface processing plan includes one of: a force profile along the trajectory, a velocity profile for the surface engaging tool along the trajectory, a rotational speed profile, for the surface engaging tool, along the trajectory, or a trajectory modification that accounts for the presence of a surface feature identified in the approximated surface topography. The process mapping system is also configured to generate a control signal for the robotic arm that includes the surface processing plan.