Automated coating system having smart end-effector tool
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.
1 . An end-effector tool mounted on a motive robot arm to apply a coating onto an object surface, the tool comprising:
an applicator configured to apply a coating onto an object surface;
one or more first sensors configured to detect a working state of the applicator, while the applicator applies the coating onto the object surface;
one or more second sensors configured to detect a travelling state of the tool, while the tool is travelling under a locomotion of the motive robot arm along the object surface; and
a tool control circuit configured to:
receive analog signals from the one or more first sensors and the one or more second sensors;
execute an analog-to-digital converter (ADC) to convert the analog signals to digital signals;
implement digital signal processing (DSP) to process the digital signals to generate travelling state information with respect to the end-effector tool, wherein the traveling state information comprises at least one of displacement information between the applicator and the object surface or mapping information of the object surface;
update one or more locomotion parameters associated with the locomotion of the motive arm along the object surface, the one or more locomotion parameters including one or more of position information, orientation information, velocity information of arm sections and/or joints of the end-effector tool, or a speed of a moving base of the end- effector tool; and
adjust the locomotion of the motive arm along the object surface as defined by the updated one or more locomotion parameters such that a trajectory of the applicator along the object surface reflects the updated one or more locomotion parameters.
2 . The end-effector tool of claim 1 , wherein the applicator includes one or more applicator heads fluidly connected to one or more cartridges to apply one or more coating materials onto the object surface.
3 . The end-effector tool of claim 2 , wherein the applicator further includes one or more air knives downstream of the applicator heads to displace, feather and cure the one or more coating materials applied onto the object surface.
4 . The end-effector tool of claim 3 , wherein the applicator further includes one or more pressurized air tanks fluidly connected to the one or more air knives to provide pressurized air.
5 . The end-effector tool of claim 1 , further comprising a mounting interface to functionally connect the tool to the motive robot arm.
6 . The end-effector tool of claim 1 , wherein the one or more first sensors include at least one of a temperature sensor, a pressure sensor, a humidity sensor, a fluid flow sensor, and an optical sensor.
7 . The end-effector tool of claim 6 , wherein the optical sensor is to detect an optical property of the coating on the object surface.
8 . The end-effector tool of claim 6 , wherein the optical sensor is located downstream of the applicator.
9 . The end-effector tool of claim 1 , wherein the one or more second sensors include one or more haptic sensors to map the object surface.
10 . The end-effector tool of claim 9 , wherein at least one of the one or more haptic sensors is located upstream of the applicator.
11 . An automated coating system comprising:
the end-effector tool of claim 1 , wherein the motive robot arm is mounted on the moving base, and wherein the tool is mounted on the motive robot arm, wherein the motive robot arm further includes a microprocessor to execute a robot controller, and wherein the control circuit of the tool communicates with the robot controller to send instructions to the robot controller to adjust the locomotion of the motive robot arm and the applicator's operation.
12 . The end-effector tool of claim 1 , wherein the motive arm is mounted on the moving base.
13 . The end-effector tool of claim 11 , wherein to adjust the adjust the locomotion of the motive arm, the tool control circuit is configured to stop operation of the motive arm.
14 . The end-effector tool of claim 13 , wherein the instructions sent to the robot controller include an emergency stop instruction.
15 . The end-effector tool of claim 14 , wherein the tool control circuit is configured to detect an emergency event based on at least one of the analog signals or the digital signals.