Smart edge sealing system and method

Abstract

A smart edge sealing system includes a control, monitoring and communication module that includes a microcontroller unit (MCU) controlling system processes. A curing and quality control module (CQCM) includes an artificial intelligence camera and a machine learning algorithm that identifies defects or inconsistencies in the coating process and communicates with the control, monitoring and communication module. A plunger sliding module is controlled by the control, monitoring and communication module based on information received from the CQCM to extrude a coating material on an edge of a workpiece.

Claims

1. A smart edge sealing system comprising: a control, monitoring and communication module that includes a microcontroller unit (MCU) controlling system processes; a curing and quality control module (CQCM) that includes an artificial intelligence camera and a machine learning algorithm that identifies defects or inconsistences in a coating process and communicates with the control, monitoring and communications module; and a plunger sliding module controlled by the control, monitoring and communications module, based on information received from the CQCM, to extrude a coating material on an edge of a workpiece, wherein the plunger sliding module is rotatable 360? degrees about the edge of the work piece, and wherein the plunger sliding module includes a replaceable injection nozzle that has a profile customized to a part edge.

2. The system as recited in claim 1, wherein the control, monitoring, and communication module adjusts a position of the plunger sliding module according to information received from the CQCM.

3. The system as recited in claim 1, wherein the CQCM further includes a marking paint jet that marks a defect area on the workpiece.

4. The system as recited in claim 1, further comprising a UV light to assist in a curing process.

5. The system as recited in claim 1, further comprising front and back distance transducers that measure height of an edge to be treated.

6. The system as recited in claim 1, wherein further comprising a motion and alignment module connected to the plunger sliding module and the workpiece.

7. The system as recited in claim 6, wherein the motion and alignment module includes sided wheels spaced apart to be positioned on either side of the workpiece.

8. The system as recited in claim 7, wherein the sided wheels include wavy damping ribs.

9. The system as recited in claim 7, wherein the sided wheels are 3D printed using TPU material.

10. A smart edge sealing method, comprising: determining a distance of a plunger sliding module from an edge portion of a workpiece through a curing and quality control module (CQCM); calculating an amount of a coating material to be extruded from the plunger sliding module onto the edge portion of the workpiece through the CQCM; and controlling the plunger sliding module based on information communicated from the CQCM to a control, monitoring and communication module, wherein the plunger sliding module is rotatable 360? degrees about the edge portion of the work piece, and wherein the plunger sliding module includes a replaceable injection nozzle that has a profile customized to a part edge.

11. The method as recited in claim 10, further comprising adjusting a position of the plunger sliding module according to information received from the CQCM through the control, monitoring and communication module.

12. The method as recited in claim 10, further comprising marking a defect area on the workpiece with a marking paint jet of the CQCM.

13. The method as recited in claim 10, further comprising curing the coating material extruded on the workpiece with a UV light.

14. The method as recited in claim 10, further comprising measuring a height of the edge portion of the workpiece using front and back transducers.

15. The method as recited in claim 10, further comprising moving the plunger sliding module with sided wheels of a motion and alignment module, the sided wheels located on either side of the workpiece.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is an illustration of an automated smart edge sealing device.

(2) FIG. 1B is a rear view of the automated smart edge sealing device.

(3) FIG. 2A and FIG. 2B are illustrations of the sided wheels.

(4) FIG. 3A is an illustration of the curing and quality control module (CQCM).

(5) FIG. 3B is an illustration of the bottom side of the CQCM having a UV light.

(6) FIG. 4 is an illustration of an injection nozzle.

(7) FIG. 5 is an illustration of the CQCM attached to the nozzle.

(8) FIG. 6A, FIG. 6B and FIG. 6C are illustrations of a semi-automated handheld edge sealing device.

(9) FIG. 7 is a flow diagram of a smart edge sealing method.

(10) Similar reference characters denote corresponding features consistently throughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(11) A self-driving machine device that automatically coats an edge surface can include wheels with integrated damping for adapting to surface changes. A motor can drive the wheels through a gear box/transmission connection. The coating material can be dispensed from a plunger sliding module held at an angle by a linear actuator and holding straps. Front and rear distance transducers can constantly measure height concerning the edge. A microcontroller unit can control the various system processes. Artificial intelligence may be used to monitor and improve the coating quality. A separate embodiment includes a handheld version of the edge sealing device.

(12) FIG. 1A is an illustration of an automated smart edge sealing device 100, and FIG. 1B is a rear view of the automated smart edge sealing device 100. In this embodiment, the smart edge sealing device 100 includes a control, monitoring and communications module 110, a motion and alignment module 120, a curing and quality control module (CQCM) 130, a plunger sliding module 140, and a power module 150.

(13) The motion and alignment module 120 includes a DC motor 121 that drives wheels 122. It also includes front and rear transducers 123,124, a hinge 125 and an upper rotating base 126.

(14) The core of the control, monitoring, and communication module 110 is an embedded microcontroller unit (MCU) that controls all system processes. Data from a variety of sensors is acquired and analyzed by the MCU. Based on the results, a decision is made to control the system actuators and achieve the desired functionality.

(15) The motion and alignment module 120 is responsible for moving and stabilizing the system. A geared DC motor 121 drives the sided wheels 122 through a mechanical transmission mechanism. Two proximity transducers 123,124 located on the device's front and rear enable the detection of the end of the edge to stop the system. Based on the feedback received from the quality control module 130, the speed is adjusted to achieve the best coating quality of the coating material 160.

(16) FIG. 2A and FIG. 2B are illustrations of the sided wheels 122 which are 3D Printed using thermoplastic polyurethane (TPU) material to perform both flexibility and strength. The sided wheels 122 have straight sides to avoid slipping, and to provide better friction and surface stability for uneven and slippery surfaces, used to count the travel linear displacement by counting the rotation angle. They have wavy damping ribs (WDR) 200 that perform damping characteristics due to the wavy shape, as well as allowing the application of a range of holding pressure on the edge while the trolley is traveling, and this will give a wide range of holding pressure due to the possible change in the edge thickness.

(17) FIG. 3A is an illustration of the curing and quality control module (CQCM) 130 which includes an artificial intelligence camera 132 mounted on the module's top. The artificial intelligence camera 132 monitors the consistency and quality of the coating material 160. A machine learning algorithm analyzes the acquired images to identify any defects or inconsistencies in the coating process. The main controller adjusts the device motion speed and coating material extrusion speed based on this feedback to achieve the best coating quality. In the case of a defect, a small marking paint jet is released on the side to mark the defect area. A UV light 134 located on the bottom of the CQCM 130, as illustrated in FIG. 3B, can be applied to the coating material 160 to help in the curing process. The CQCM 130 could be easily attached and detached with a set of clips 136. Connection terminals 138 are also provided on a top portion of the CQCM 130.

(18) The power module 150 provides the required power for system operations and includes batteries, a charging unit and a power regulation unit.

(19) The plunger sliding module (PSM) 140, as illustrated in FIG. 1A and FIG. 1B, includes a coating material plunger (container/syringe) 141 and uses two holding straps 142 for easy replacement. A replaceable injection nozzle 143 is attached to the head of the plunger. The injection nozzle 143, as illustrated in FIG. 4, has a profile 144 that is customized to a certain part edge. The nozzle further includes a threaded neck 145. The Curing and Quality Control Module (CQCM) 130 is attached to the top of the nozzle 143 as illustrated in FIG. 5.

(20) The coating material is extruded from the plunger 140 through a linear actuation mechanism 146 that is driven by an electrical motor. The speed of extrusion is adjusted based on the feedback from the quality control module.

(21) Front and back distance transducers 123,124 (that can, by way of non-limiting example, be IR sensors, Ultrasound, or any other distance sensor) constantly measure the height concerning the edge. This information is communicated to the main controller 110 to adjust the height of the injection nozzle to maintain the standard gap between the nozzle and the edge for optimum coating results. Adjusting the height of the nozzle is achieved by adjusting the tilting angle of the Plunger Sliding Module (PSM) 140 employing a linear actuation mechanism 170. In addition, PSM 140 can be rotated 360 degrees utilizing an upper rotational base 126, which enables it to perform coating operations in both directions to cover the entire edge surface.

(22) FIG. 6A, FIG. 6B and FIG. 6C are illustrations of a semi-automated handheld edge sealing device 600. It enables the users to manually perform coating on specific areas such as areas with defect coats or hard areas that cannot be reached using an automated setup. It includes a plunger 610 having an injection nozzle 612, a linear motor 614, a sliding module 616 and strip slots 618. The plunger 610 slides into a hand held base 620, as illustrated in FIG. 6B, through sliding module 616. The coating material extrusion is automated employing a linear actuation mechanism through linear motor 614. Also, the plunger 610 is attached to the sliding module 616 using strip slots 618 and straps 630 as illustrated in FIG. 6C.

(23) The smart edge sealing device can include a fully automated mode and a semi-automated handheld mode. It can be equipped with a quality control machine learning vision system that monitors, identifies and locates (by marking and recording the position) areas or spots with coating defects, in addition, to taking corrective actions by adjusting the device motion speed and the coating injection speed to achieve the desired coating quality.

(24) The fully automated device can be equipped with specially designed 3D printed sliding wheels using TPU material to perform both flexibility and strength. The wheels can have straight sides to avoid slipping, and provide better friction and surface stability for uneven and slippery surfaces, used to count the travel linear displacement by counting the rotation angle.

(25) The wheels can have wavy damping rips (WDR) that perform damping characteristics due to the wavy shape, as well as allow applying a range of holding pressure on the edge while the system is traveling, and this will give a wide range of holding pressure due to the possible change in the edge thickness.

(26) The coating material can be extruded from the plunger using a linear actuation mechanism driven by an electrical motor. The speed of extrusion can be adjusted based on feedback from the quality control module.

(27) The system can maintain a constant height between the edge and the injection nozzle based on the edge profile measured by front and back distance transducers (that can be IR sensors, Ultrasound, or any other distance sensor). Adjusting the height of the nozzle is achieved by adjusting the tilting angle of the Plunger Sliding Module (PSM) employing a linear actuation mechanism.

(28) The plunger can be rotated 360 degrees utilizing an upper rotational base, which enables it to perform coating operations in both directions to cover the entire edge surface.

(29) The smart edge sealing device can provide enhanced durability. Composite edge sealing can help protect against moisture ingress, delamination, and environmental factors, thereby improving the durability and longevity of composite structures.

(30) Improved performance can be achieved by preventing damage and maintaining the structural integrity of composite materials, edge sealing can contribute to better overall performance in terms of strength, stiffness, and resistance to degradation.

(31) Edge sealing technology can provide protection against corrosion. It can provide a barrier against corrosive substances, particularly in industries such as automotive and marine, where composites are exposed to harsh environments.

(32) Different edge sealing techniques and materials can be tailored to specific composite applications, allowing for customization and optimization of performance.

(33) FIG. 7 is a flow diagram of a smart edge sealing method. The distance of a plunger sliding module from an edge portion of a workpiece is determined, in box 710, through a curing and quality control module (CQCM). An amount of a coating material to be extruded from the plunging sliding module onto the edge of the workpiece is calculated, in box 720, through the CQCM. The plunger sliding module is controlled, in box 730, based on information communicated from the CQCM to a control monitoring and communication module to extrude coating material onto the edge of the workpiece.

(34) The method further includes adjusting the position of the plunger sliding module according to information received from the CQCM through the control monitoring and communication module.

(35) The method further includes marking a defect area on the workpiece with a marking paint jet of the CQCM.

(36) The method further includes curing the coating material extruded on the workpiece with a UV light.

(37) The method further includes measuring the height of the edge of the workpiece using front and back distance transducers.

(38) The method further includes moving the plunger sliding module with sided wheels of a motion and alignment module. The sided wheels being located on either side of the workpiece.

(39) Edge sealing technology is a valuable tool for manufacturers of composite materials. It can help to improve the quality and performance of their products, and it can also help to reduce costs.

(40) A smart edge sealing device is a general-purpose device that provides coating and quality control for different applications, especially industrial and aerospace industries and composite materials. It supports coating and protection processing of edges and cut boards of composites. It includes the following advantageous features: Easy to use and can be integrated with any applications; Economic and environmentally friendly since it uses green and recyclable materials. Adaptable and can be easily used for different edge sizes as well as without any restrictions and limitations. Easy to use and assemble without the need to any experience. Reliable and easy to maintain since made from 3D-printed connected parts. Lightweight because it is made from a green polymeric material. Uses an open source design and material that makes it affordable, and cheap.

(41) It is to be understood that the smart edge sealing system and method with quality control features is not limited to the specific embodiments described above, but encompasses any and all embodiments within the scope of the generic language of the following claims enabled by the embodiments described herein, or otherwise shown in the drawings or described above in terms sufficient to enable one of ordinary skill in the art to make and use the claimed subject matter.