Painting system

Abstract

A coating system for applying coating liquid such as a base coat, a paint, a lacquer or a protective layer to surfaces of buildings, wind turbines, ships and aircraft. The coating system includes an unmanned aerial machine in the form of a helicopter for dispensing the coating liquid. The aerial machine has a fuselage, two rotors, a tank for holding the coating liquid, and an applicator for dispensing the coating liquid and outputting same onto a surface to be coated. In order to supply the tank with coating liquid, the tank is fastened to the aerial vehicle and the tank or aerial vehicle has a filling opening for refilling the tank in the landed state of the vehicle, and/or the tank is part of an exchangeable tank module coupled to the fuselage and/or is uncoupled from the fuselage by a coupling device controlled in an automated manner.

Claims

1. A coating system for applying a base coat, a paint, a lacquer or a protective layer to a surface to be coated, said coating system comprising: a tank for holding a coating liquid before discharge; an applicator for dispensing the coating liquid, the coating liquid being supplied from said tank and output onto the surface to be coated through said applicator; an unmanned aerial vehicle comprising a helicopter for outputting the coating liquid to the surface to be coated, said unmanned aerial vehicle comprising a fuselage and at least two rotors; a base station comprising a landing area configured for receiving said unmanned aerial vehicle thereon, said unmanned aerial vehicle being in a landed state when disposed on said landing area of said base station; and a fixing mechanism cooperating between said base station and said unmanned aerial vehicle, said fixing mechanism being configured to secure said unmanned aerial vehicle against vertical displacement relative to said base station when in the landed state on said landing area thereof; wherein said tank is fastened to said unmanned aerial vehicle and is either configured for refilling in the landed state of said unmanned aerial vehicle while said tank is fastened thereto or said tank comprises a tank module configured for releasable coupling to said fuselage to permit exchange of said tank module in the landed state of said unmanned aerial vehicle.

2. The coating system of claim 1, wherein said tank comprises said tank module, said tank module being configured for releasable and automated coupling to said fuselage by a tank module coupling device configured for automated control.

3. The coating system of claim 2, further comprising a coupling arrangement comprising said tank module coupling device and cooperating between said base station and said unmanned aerial vehicle, said coupling arrangement including a section disposed on said base station adjacent said landing area thereof, said section engaging said tank module coupling device in the landed state of said unmanned aerial vehicle to move said tank module coupling device from a coupled state to a released state to permit exchange of said tank module.

4. The coating system of claim 1, wherein said applicator comprises an applicator module having an exchangeable configuration to permit coupling of said applicator module to said fuselage and uncoupling of said applicator module from said fuselage by an applicator module coupling device configured for automated control.

5. The coating system of claim 1, wherein said unmanned aerial vehicle comprises an electrical energy supply module and said coating system comprises an energy supply module coupling device configured for automated control, said electrical energy supply module being configured for coupling to said fuselage and uncoupling from said fuselage by said energy supply module coupling device.

6. The coating system of claim 5, wherein said tank comprises said tank module, said tank module being configured for releasable coupling to said fuselage by a tank module coupling device configured for automated control, said electrical energy supply module and said tank module comprising an integral tank and energy supply module and said tank module coupling device and said energy supply module coupling device comprise a common coupling device.

7. The coating system of claim 1, wherein said unmanned aerial vehicle comprises at least one internal combustion engine for driving said at least two rotors or for driving an electrical energy generator.

8. The coating system of claim 7, wherein said unmanned aerial vehicle comprises a fuel module configured to supply said internal combustion engine with fuel.

9. The coating system of claim 1, wherein said applicator comprises a guide device configured to reduce disturbance, due to turbulence caused by said at least two rotors, of a coating spray jet dispensed from said applicator in a dispensing direction.

10. The coating system of claim 9, wherein said applicator defines a dispensing axis and said guide device surrounds the dispensing axis.

11. The coating system of claim 1, wherein said applicator is pivotably movable relative to said fuselage.

12. The coating system of claim 11, wherein said applicator is pivotably movable about a horizontal pivot axis at an angle permitting downward pivoting of said applicator between a first orientation in which said applicator outputs a substantially horizontally oriented spray jet and a second orientation in which said applicator outputs a substantially vertically oriented spray jet.

13. The coating system of claim 1, wherein said unmanned aerial vehicle comprises a layer thickness sensor unit configured to contactlessly measure an applied layer of coating liquid.

14. The coating system of claim 1, wherein said unmanned aerial vehicle comprises an application compensator configured to compensate for a pulse generated during dispensing of the coating liquid.

15. The coating system of claim 14, wherein said application compensator comprises one of an additional rotor having a rotation axis with an orientation different from a vertical direction, or a guide device displaceable relative to said fuselage and in relation to an air stream of at least one of said at least two rotors to deflect the air stream flowing to or departing from said at least one rotor.

16. The coating system of claim 1, wherein said base station comprises a mechanically-acting positioning mechanism configured to position said unmanned aerial vehicle in a defined service position when in the landed state.

17. The coating system of claim 16, wherein said mechanically-acting positioning system comprises a passive positioning mechanism including guide surfaces inclined in relation to a vertical direction, said guide surfaces interacting with said unmanned aerial vehicle during landing thereof to horizontally displace said unmanned aerial vehicle.

18. The coating system of claim 1, wherein said fixing mechanism comprises at least one securing element configured to cooperate with a mating area on said unmanned aerial vehicle during landing thereof, said at least one securing element being displaceable in an automated manner in a displacement direction into engagement with said mating area to secure said unmanned aerial vehicle against vertical displacement relative to said base station.

19. The coating system of claim 18, wherein said at least one securing element is displaceable translatively or pivotably.

20. The coating system of claim 18, wherein said at least one securing element includes a threaded area configured to cooperate with a threaded area of said mating area of said unmanned aerial vehicle to secure said unmanned aerial vehicle against vertical displacement relative to said base station.

21. The coating system of claim 18, wherein said at least one securing element has an inclined area configured to cooperate with an inclined area of said mating area of said unmanned aerial vehicle such that displacement of said at least one securing element causes a force to be applied to said unmanned aerial vehicle in a direction corresponding to the displacement direction of said securing element and in a direction transverse to the displacement direction.

22. The coating system of claim 18, wherein said fixing mechanism comprises a locking member and said at least one securing element comprises a plurality of said securing elements, wherein relative movement between said locking member and said plurality of securing elements causes simultaneous radial displacement of said plurality of securing elements to secure said unmanned aerial vehicle against vertical displacement relative to said base station.

23. The coating system of claim 1, wherein: said at least two rotors comprises at least three downwardly-directed rotors; or said unmanned aerial vehicle comprises a measurement system configured to measure a quantity of liquid dispensed from said tank or a quantity of coating liquid contained in said tank, and an attitude controller including software configured to evaluate measurements taken by said measurement system; or said tank comprises a thermally-insulated tank with an insulated outer wall; or said unmanned aerial vehicle comprises a heating device to heat the coating liquid before application thereof by said applicator; or said applicator has a dispensing opening for outputting the coating liquid to a surrounding area, said applicator being disposed or configured such that said dispensing opening, or a guide device of said applicator, is spaced apart from said at least two rotors by at least 20 cm with respect to a horizontal plane; or said unmanned aerial vehicle comprises at least one camera oriented horizontally so as to detect surfaces to be coated with the coating liquid and configured to output data for use in positioning said unmanned aerial vehicle relative to the surface to be coated.

24. A coating system for applying a base coat, a paint, a lacquer or a protective layer to a surface to be coated, said coating system comprising: a tank for holding a coating liquid before discharge; an applicator for dispensing the coating liquid, the coating liquid being supplied from said tank and output onto the surface to be coated through said applicator; an unmanned aerial vehicle comprising a helicopter for outputting the coating liquid to the surface to be coated, said unmanned aerial vehicle comprising a fuselage and at least two rotors; and a base station comprising a landing area configured for receiving said unmanned aerial vehicle thereon, said unmanned aerial vehicle being in a landed state when disposed on said landing area of said base station, said base station comprising a plurality of exchangeable modules including two or more of the following: a tank module incorporating said tank; an electrical energy supply module; a fuel module; or an applicator module incorporating said applicator, each said exchangeable module being movable to a transfer position on said base station, said base station further comprising an automated handling mechanism, and each said exchangeable module in said transfer position on said base station being couplable to said fuselage of said unmanned aerial vehicle by said automated handling mechanism.

25. The coating system of claim 24, wherein said tank is permanently mounted on said unmanned aerial vehicle and said unmanned aerial vehicle or said tank has a filling opening disposed to permit refilling of said tank in the landed state of said unmanned aerial vehicle on said base station.

26. The coating system of claim 24, wherein one of said plurality of exchangeable modules comprises said tank module incorporating said tank.

27. The coating system of claim 24, wherein said automated handling mechanism comprises a movable magazine disposed on said base station, and said plurality of exchangeable modules are disposed in said movable magazine.

28. The coating system of claim 27, wherein said movable magazine comprises a turret.

29. The coating system of claim 24, wherein said base station is configured to heat contents of at least one of said plurality of exchangeable modules.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages and aspects of the invention can be found in the claims and the following description of preferred exemplary embodiments of the invention which are explained below with reference to the figures.

(2) FIG. 1 shows an exemplary embodiment of a coating system according to the invention having a base station and an aerial vehicle.

(3) FIGS. 2 to 4 show the aerial vehicle of the coating system from above and also from two lateral perspectives.

(4) FIGS. 5A and 5B show the aerial vehicle during coating of an object.

(5) FIGS. 6A to 6E show the coating system including the base station during landing and starting of the aerial vehicle.

(6) FIG. 7 shows an exemplary refinement of a base station from above.

(7) FIGS. 8A and 8B show an alternative design of the coating system.

(8) FIG. 9 shows a further alternative design of the coating system.

(9) FIGS. 10A to 13C show four variants of a locking system for the base station.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

(10) FIG. 1 shows a coating system 10 according to the invention. This coating system has an aerial vehicle 20 on which an applicator module 40 is provided. The coating system 10 further has a base station 100 which is intended to be set up in a stationary or mobile manner on the ground and also serves as a landing platform for the aerial vehicle 20.

(11) The components of the aerial vehicle 20 are explained in more detail in a schematic manner with reference to FIGS. 2 to 4.

(12) The aerial vehicle is designed as an octocopter. This means that the aerial vehicle has a total of eight rotors which, in a manner driven by respectively dedicated electric motors 25 and fitted to cantilever arms 23, implement lifting of the aerial vehicle 20, which lifting is required for flight. The aerial vehicle 20 has a fuselage to which, in addition to the cantilever arms 23 on the bottom side, various modules which will be explained in more detail below are fitted.

(13) Furthermore, the aerial vehicle 20 has a total of four landing feet 90.

(14) Depending on the configuration of the aerial vehicle, said modules are a tank module 30 for holding the coating liquid, an energy supply module 50 for holding batteries or rechargeable batteries, an applicator module 40 for dispensing the coating fluid and, but not in the exemplary embodiment illustrated in FIGS. 2 to 4, a fuel module 60 for supplying an internal combustion engine of the aerial vehicle 20.

(15) In the configuration according to FIGS. 2 to 4, a common module 30, 50 is provided, which common module combines the tank module 30 for the coating liquid and the energy supply module 50 for holding electrically stored energy. This common module 30, 50 is coupled to the fuselage 22 in an exchangeable manner by means of coupling devices 34, 54. The tank module 30 comprises the tank for holding the coating liquid, a measurement system 38 for detecting the filling level and also a filling opening 36 which is usually closed by a non-return valve. The applicator module 40, which is usually designed to be longer than as depicted in the illustrations, comprises the actual applicator 42 for outputting the liquid, which applicator has a dispensing opening 42C for this purpose. The applicator 42 is surrounded by a funnel-like guide device 43 which is oriented in a manner corresponding to the opening angle of the liquid jet which is output by the dispensing opening 42C. The applicator module 40 further comprises a motor 45, for example a servomotor, in order to be able to pivot the applicator 42 about the axis 42A.

(16) An application compensator 47 in the form of a further rotor 48 is provided on that side of the applicator module 40 which is averted from the applicator.

(17) As illustrated in FIG. 2, a connecting line 27 is provided, which connecting line connects the tank 32 to the applicator module 40 and is provided for feeding the applicator 42. The line is provided with a pumping device 29 and a heating device 28. The heating device allows the liquid which is pumped out of the tank 32 by means of the pumping device 29 to be heated before it is dispensed. This is provided depending on the type of coating liquid which is to be dispensed and/or depending on the ambient temperature.

(18) The aerial vehicle 20 is provided for coating surfaces of large area, wherein different types of coating are possible, for example applying a colored paint, a base coat or else applying a corrosion-protection agent or corrosion-protection wax.

(19) The use of the aerial vehicle 20 takes place as explained, by way of example, with reference to FIGS. 5A and 5B. FIG. 5A illustrates how the aerial vehicle 20 coats a surface 200, that is to say for example applies a layer of paint 202, using the applicator module 40. To this end, the liquid which is supplied from the tank 32 by means of the pumping device 29 is dispensed through the dispensing opening 42C in atomized form in the direction of the dispensing axis 42B. In this case, the guide device 43 in the form of a funnel prevents the air movement which is caused by the rotors 24 from appreciably disturbing the spray jet. Precise coating is possible in this way.

(20) The aerial vehicle 20 has a camera 74 and a layer thickness sensor unit 72. A control device 80 can use the output signals from said camera and layer thickness sensor unit during the discharge of the coating liquid in order to check whether the applied layer meets the requirements or in order to be able to navigate in a particularly precise manner by evaluating a camera image.

(21) During dispensing of the coating liquid, the rotor 48 is activated in order to compensate for the pulse which is caused by the dispensing operation. Although this is also possible with the lifting rotors 24 in principle, the aerial vehicle 20 would have to be moved to a more tilted position, which would make dispensing of liquid more difficult.

(22) FIG. 5B shows that, with a changed orientation of the surface 200 which is to be coated, the aerial vehicle 20 ensures, due to reorientation of the applicator 42, that the application of the coating continues at an ideal angle and in a manner protected against the turbulent air of the rotors 24.

(23) FIGS. 6A to 6E show temporary landing of the aerial vehicle 20 for the purpose of refreshing the operating resources.

(24) FIG. 6A shows the aerial vehicle 20 during the landing approach. Owing to a downwardly directed camera, not illustrated, or else other navigation and positioning mechanisms, the aerial vehicle 20 positions itself above the base station 100 and then reduces the altitude. In the process, the landing feet 90 engage with a positioning mechanism 102, which is shaped in the form of a funnel, as intended. The guide faces 104, which form the funnel, are correspondingly inclined so that a precise predetermined position can be assumed even in the event of an inaccurate approach by the aerial vehicle 20 in the manner shown by FIG. 6B.

(25) During landing, the modules 30, 50, 40 enter shafts which are provided on the base station 100, and said modules are then arranged above magazines 132 which are still to be explained below. As soon as the landing feet 90 of the aerial vehicle 20 have reached their desired position, pin-like securing elements 112 of a fixing mechanism 110 are radially extended in order to completely fix the aerial vehicle 20 by way of interaction with mating areas 92 on the landing feet 90, so that said aerial vehicle is secured against lifting away in an interlocking manner.

(26) In a manner not illustrated in any detail, electrical contact areas on the base station 100 and the aerial vehicle 20 are connected to one another during landing, so that the control device 80 of the aerial vehicle 20 can be supplied with electrical power by means of said contact areas.

(27) Furthermore, the landing process leads to pin-like sections 120 which are provided on the top side of the base station coming into contact with components 34A, 44A, 54A of the coupling devices 34, 44, 54 which are provided for this purpose and in this way allow the modules 30, 50, 40 to be uncoupled in a mechanical manner. As a result, it is possible for the control device 80 or a base station-side control device to release the coupling devices 34, 44, 54, so that both the combined tank module and energy supply module 30, 50 and also the applicator module 40 are unlatched and drop into their respective magazine 132.

(28) By moving this magazine 132, a new module 30, 40, 50 is then, in the manner shown in FIG. 6D, respectively moved to a transfer position below the aerial vehicle 20 and raised there by means of a mechanism 130 which is not illustrated in any detail (and instead is shown diagrammatically), so that coupling of the coupling devices 34, 44, 54 takes place. The coupling devices 34, 44, 54 are preferably designed in such a way that a coupled state is achieved solely by pressing against the respective module, in particular by way of the module-side elements of the coupling device locking into place in a unidirectional manner when the fuselage 22 is pressed against.

(29) As illustrated in FIG. 6E, the aerial vehicle 20 can be restarted and continue applying the coating after the securing elements 112 are released.

(30) FIG. 7 shows a schematic illustration of the base station 100 from above. It can be seen that the magazines for holding the combined tank and energy supply modules 30, 50 and, respectively, the applicator modules 40 are configured differently in the present case. The magazine 132 for the combined modules 30, 50 is designed as a turret magazine, whereas the magazine 132 for the applicator modules 40 is designed as a linearly oriented magazine 132. The two magazines 132 share the common feature that they are respectively configured in a movable manner in accordance with the arrows 140, 142.

(31) FIGS. 8A and 8B and also 9 show slightly modified variations. An additional or alternative option for refilling the tank 32 is provided in the case of the design of FIGS. 8A and 8B. Here, the base station 100 has a filling section 150 which is connected into a coating liquid supply system 152. When the aerial vehicle 20 is landed, this section enters the filling opening 36 of the aerial vehicle 20 and in the process opens the non-return valve which is provided here. The tank 32 can then be refilled without exchanging the module.

(32) FIG. 9 shows a variant in which a supplementary or additional internal combustion engine 82 is provided in the drone. Furthermore, a fuel module 60 is provided in this refinement for supplying the internal combustion engine 82, which fuel module is part of an integral module 30, 50 for the coating liquid and the fuel. In this case, filling openings 36, 66 are respectively provided on the bottom side of this module 30, 50 for refilling purposes.

(33) FIGS. 10A and 10B, 11A and 11B, 12A and 12B and also 13A to 13C show alternative variants of a fixing mechanism 110 which can be used instead of those of the design illustrated in FIG. 6B.

(34) In the variant of FIGS. 10A and 10B, the fixing mechanism has pivotable securing elements 114 which are designed in a hook-like manner in the present case. After landing or in the last phase of landing of the aerial vehicle 20, these securing elements project in a motor-driven manner out of the position of FIG. 10A to that of FIG. 10B. In the process, they fix a holding cam 91 which is respectively provided on the landing foot 90. The aerial vehicle 20 is then secured against lifting away in an interlocking manner.

(35) In the variant of FIGS. 11A and 11B, the landing feet 90 are provided with an external thread 94. In a manner corresponding to this, a securing element 115 of the base station 100 is configured in the form of a rotatable nut with an internal thread 116 and provided such that it can be rotated on the base station 100 by a motor. When the aerial vehicle 20 is landed, the landing feet enter, by way of the external thread 94, the bore of the securing element 115 and are firmly screwed here by the rotational movement of said securing element 115.

(36) The variant of FIGS. 12A and 12B makes provision for inclined holding areas or a circumferential conical area 96 to be provided on the landing feet. In order to interact with said holding areas or conical area, the base station has radially displaceable securing elements 117 which can be displaced horizontally in relation to the inserted landing feet of the aerial vehicle 20 by motor and likewise have an inclined holding area, so that said holding areas, as they approach one another and in the direction of the respective landing foot 90, apply force to said landing foot radially inwardly and as a result axially downwardly. The landing feet of the aerial vehicle 20 are pushed against a stop face of the base station 100 in the process, so that secure fixing of the aerial vehicle 20 is achieved.

(37) The variants of FIGS. 13A to 13C provide a securing device which, on the base station 100, consists of a pipe 118A, which is provided with radial cutouts, and securing bodies 118B which can be radially displaced in relation to said pipe. A locking pin 119 is provided within the pipe 118A, which locking pin can be displaced in the direction of extent of the pipe 118A by a motor in order to push the securing bodies 118B outward by means of its conical end during this movement.

(38) In a corresponding manner to this, the landing feet 90 are also provided with a widening securing geometry.

(39) When the vehicle 20 is landed, as shown in FIG. 13B, the locking pin 119 is moved upward. In the process, the spherical securing bodies 118B are displaced and shift outward. As a result, they protrude beyond the outside diameter of the pipe 118A on the outside, so that they form an interlocking securing arrangement with the widening geometry of the landing feet 90.