Vision-Guided Robotic Tire Spraying System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for coating green or uncured tires are laborious and inefficient, requiring manual application and separate apparatuses for different tire sizes, with high overspray and material waste, and lack flexibility to handle varying tire profiles.
Innovation Solution
A robotic spray system utilizing an integrated vision system to analyze individual tires and dynamically adjust spray positions, fluid, fan, and atomizing air for precise coating on both inside and outside surfaces, capable of handling any size or shape without part-specific setup, incorporating a conveyor system and cameras for accurate positioning and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual spraying or brushing is used to apply coatings, then the application process is simple and flexible, but the process is time-consuming and laborious with low productivity
Solution Approach 1:
The patent replaces manual mechanical spraying/brushing operations with an automated robotic spray system that uses computer vision guidance. The robot arm with spray nozzle is controlled by a vision system that processes tire images to determine precise coating locations, eliminating manual labor while maintaining operational simplicity through automated image-based positioning.
2Manufacturing precision
If separate applicator apparatuses are used for different tire sizes, then each apparatus can be optimized for specific tire dimensions, but the device complexity increases and adaptability decreases
Solution Approach 1:
The patent implements a universal robotic spray system that can handle multiple tire sizes and configurations through a single apparatus. The vision system captures images of each tire, processes the dimensions and geometry, and dynamically adjusts spray positions and parameters, allowing one system to perform multiple functions across different tire types without requiring separate specialized equipment.
Solution Approach 2:
The system dynamically adapts to different tire sizes and shapes by processing real-time images and adjusting spray parameters on-the-fly. The robot arm positions, spray nozzle angles, and coating application patterns are dynamically modified based on vision system analysis of each specific tire geometry, enabling precise coating without fixed apparatus configurations.
3Device complexity
If conventional spraying methods are used, then the equipment is simple, but overspray is high and material waste increases
Solution Approach 1:
The system incorporates vision system feedback that analyzes each tire's actual geometry and positioning. The processed image data feeds back to the robot control system, which adjusts spray parameters in real-time to match the specific tire features, ensuring coating is applied only where needed and minimizing overspray and material waste.
Solution Approach 2:
The vision-guided system applies coating with local precision by identifying specific areas that require coating based on image analysis. The robot selectively sprays only the necessary portions of the tire surface determined by the vision system, rather than applying coating uniformly or broadly, thereby reducing material waste while maintaining coating quality where required.
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 significantly reduces overspray and material costs, enabling efficient coating of green tires every 7-14 seconds with minimal waste, providing flexibility to handle diverse tire sizes and profiles, and can be retrofitted into existing systems.
Implementation Method 1
The system analyzes individual green tires using an integrated vision system
Implementation Method 2
A robotic spray system utilizing an integrated vision system to analyze individual tires and dynamically adjust spray positions, fluid, fan, and atomizing air for precise coating
Implementation Method 3
The system controls the robotic spray position, the fan, fluid, atomizing air, and tire rotation speed for optimal spray coverage
Data Source
AI summary
A robotic spray system is provided for accurately spraying mold release onto any size or shaped green tire. The system analyzes individual green tires using an integrated vision system. The system controls the robotic spray position, the fan, fluid, atomizing air, and tire rotation speed for optimal spray coverage on both the inside and outside of green tires. The system includes a conveyor, an overhead mounted camera located over an infeed station, and a second camera located perpendicular to the green tire's tread and several feet away from the center of the tire. Pictures of the green tire in the station are used to estimate the center and radius of the tire and locate the angle of the bar code with respect to the center of the tire. Reference points are provided from the camera images and robot positions are calculated to control the spraying.