Smart End-Effector Coating Control for Wind Blade Precision
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Solution Overview
Problem
Current processes for applying protective coatings on wind turbine blades are time-consuming and labor-intensive, requiring manual application of polyurethane coatings which can be inefficient.
Innovation Solution
An automated coating system utilizing a smart end-effector tool mounted on a motive robot arm, equipped with sensors to detect working and traveling states, and a control circuit to process signals for real-time adjustments in movement and operation, enabling precise and autonomous application of coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual coating processes are used, then labor flexibility is maintained, but productivity is low and time consumption is high
Solution Approach 1:
The end-effector tool is equipped with sensors that autonomously detect its own working state and traveling state, and the control circuit automatically processes this data to generate state information without requiring external monitoring or manual intervention, enabling the system to self-manage its operational status
Solution Approach 2:
The system incorporates sensors that continuously monitor the applicator's working state and the tool's traveling state, feeding this information back to the control circuit which processes the signals to generate real-time state information, creating a closed-loop control system that automatically adjusts to maintain optimal coating application
2Manufacturing precision
If automated coating systems are implemented, then productivity increases, but real-time control precision is reduced
Solution Approach 1:
The control circuit is pre-configured with the logic and algorithms necessary to process sensor signals and generate state information, allowing it to immediately analyze and respond to changing conditions without requiring complex real-time computations or external processing delays
Solution Approach 2:
The control system is divided into distinct functional modules: sensors for detection, control circuit for signal processing and state information generation, and actuation mechanisms for applying coatings. This segmentation allows each component to operate independently and efficiently, reducing overall system response time while maintaining precision
3Measurement precision
If sensor integration is added to the tool, then state detection capability is improved, but device complexity increases
Solution Approach 1:
The end-effector tool is designed with multi-functional integration where the same tool structure houses both the coating applicator and the sensor array, allowing the tool to simultaneously perform coating application and self-monitoring functions without requiring separate dedicated devices for each function
Solution Approach 2:
The control circuit integrates multiple sensor signals from different sensors into a unified state information output, combining the working state detection and traveling state detection functions into a single processing unit that generates comprehensive tool state information
Data Source
AI summary
Automated systems and methods of using a smart end-effector tool (20) including an applicator (30) to apply a coating onto an object surface (2) (e.g., a wind blade) are provided. The smart tool (20) can process on-board sensor signals and update its working state with a remote robot controller (28) in real time and send instructions to the robot controller (28) to adjust the tool's travelling around the object surface (2) and optimize the applicator's (30) operation.