WO2008092799A1 - Remplissage automatisé d'enfoncements - Google Patents

Remplissage automatisé d'enfoncements Download PDF

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Publication number
WO2008092799A1
WO2008092799A1 PCT/EP2008/050843 EP2008050843W WO2008092799A1 WO 2008092799 A1 WO2008092799 A1 WO 2008092799A1 EP 2008050843 W EP2008050843 W EP 2008050843W WO 2008092799 A1 WO2008092799 A1 WO 2008092799A1
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WO
WIPO (PCT)
Prior art keywords
geometry
dent
determination
layers
filler composition
Prior art date
Application number
PCT/EP2008/050843
Other languages
English (en)
Inventor
Stefan Leonardus Maria Van Diessen
Huig Klinkenberg
Maarten Van Pul
Original Assignee
Akzo Nobel Coatings International B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Akzo Nobel Coatings International B.V. filed Critical Akzo Nobel Coatings International B.V.
Publication of WO2008092799A1 publication Critical patent/WO2008092799A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/02—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using liquid or paste-like material
    • B29C73/025—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using liquid or paste-like material fed under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C2037/90—Measuring, controlling or regulating
    • B29C2037/903—Measuring, controlling or regulating by means of a computer

Definitions

  • the invention relates to a process for automated filling of a dent in a three- dimensionally shaped damaged substrate.
  • the invention also relates to a system suitable for carrying out the process.
  • United States patent US 4416068 a process for automated filling of a dent in a three-dimensionally shaped damaged substrate with a hardenable filler composition.
  • the use of computer controlled robotic equipment for analyzing surface imperfections, fairing, applying a sprayable fairing compound, and painting is known from United States patent US 6365221 B.
  • Fairing is a process whereby a less than smooth surface is filled, sanded, and primed in preparation for painting in order to improve the aesthetic quality of the exterior paint finish of marine vessels, in particular yachts.
  • the known fairing process is only suitable for smoothing minor surface imperfections.
  • the precise filling of individual dents caused by damage so as to match the original surface contours of a damaged substrate, such as a dent in an automobile caused by a collision is not possible with the known fairing process.
  • labour costs account for an increasing part of the total repair costs.
  • the present invention seeks to provide an automated process suitable for the precise filling of individual dents caused by damage so as to match the original surface contours of a damaged substrate.
  • the process should reduce the labour costs and time of an automobile collision repair.
  • the invention provides a process for automated filling of a dent in a three- dimensionally shaped damaged substrate with a hardenable filler composition comprising the steps of a) determination of the actual geometry of the surface of the dent, b) determination of the desired surface geometry after filling of the dent, c) calculation of the difference in geometry between the actual geometry of the surface of the dent and the desired surface geometry and calculation of the volume and geometry to be filled and determination of the position and orientation thereof in space, d) determination whether the volume determined in step c) is below or equal to a predetermined value and i) if the difference is below or equal to the predetermined value, stopping the process, and ii) if the difference is above the predetermined value, continuation with steps e) to g), e) calculation, on the basis of the calculated volume and geometry to be filled, of layers h to I n corresponding to the volumes and geometries required to fill the dent, wherein n is an integer corresponding to the number of layers required to fill the dent
  • the process is suitable for the precise filling of individual dents caused by damage so as to match the original surface contours of a damaged substrate.
  • the process reduces the labour costs and time of an automobile collision repair.
  • the presently used filler compositions often contain styrene or other toxicologically worrisome substances.
  • the automated process according to the invention minimizes or eliminates the exposure of workers to the toxic substances present in filler compositions.
  • the actual geometry of the surface of the dent to be filled can be determined by any suitable technology available. Examples of suitable technologies are point based techniques, line based techniques, and area based techniques. Generally, determination of the geometry of the surface of the dent can be carried out using contact methods or non-contact methods. A typical industrially applied contact method is implemented in a coordinate measuring machine. Further examples of suitable contact methods are the use of a touch probe or a linear position sensor, such as a linear variable differential transformer (LVDT).
  • LVDT linear variable differential transformer
  • Suitable non-contact methods are laser thangulation, time of flight measurements which use time as a surrogate measure for distance, fringe projection, X-ray, photogrammetry, and interferometry.
  • These and other surface geometry determination methods are generally known, for example from the thesis of G. Bradshaw, Non-Contact Surface Geometry Measurement Techniques, Trinity College, Dublin, Ireland, 1998/1999.
  • the geometry of the surface surrounding the damaged area can be determined.
  • the geometry determination of step a) is suitably carried out by a geometry determination unit.
  • the geometry determination unit and the three-dimensionally shaped damaged substrate are moveable with respect to each other.
  • the geometry determination unit suitably is a computer controlled robotic unit.
  • the geometry determination unit can be attached to a robotic arm moveable about various control axes.
  • the geometry determination unit can be fixed and the substrate is moveable about various control axes. It is also possible that both the substrate and the geometry determination unit are moveable.
  • the determined geometry data are generally transmitted from the geometry determination unit to an input unit of a data storage and processing unit capable of reading and processing the geometry data.
  • the desired surface geometry after filling of the dent is determined.
  • the desired surface geometry after filling of the dent is identical to or very similar to the original surface geometry before the damage occurred.
  • the desired surface geometry after filling of the dent can be determined by a reverse engineering step, such as extrapolation on the basis of the surface surrounding the dent.
  • this method can be very suitable to determine the original surface geometry at the location of the dent.
  • the surface geometry of some areas of automobiles, such as door panels, hoods, or roofs can often be described by relatively simple geometrical functions. If the damaged area is sufficiently small, it can sometimes even be approximated as a plane. For such cases extrapolation from the surface surrounding the dent can give a very reliable approximation of the desired surface geometry after filling of the dent.
  • CAD computer aided design
  • Determination of the desired surface geometry after filling of the dent is suitably carried out by a data storage and processing unit under the control of a program.
  • the difference in geometry between the actual geometry of the surface of the dent and the desired surface geometry can be calculated by subtracting the geometry data of the damaged surface from the desired surface geometry data.
  • the result of this step is a volume and geometry that has to be filled with filler composition, and the position and orientation thereof in space. This step is generally carried our by the data storage and processing unit mentioned above.
  • a value of the difference in geometry is predetermined below which no further filling is required.
  • the dent filling process is stopped or not even started. If the difference is above the predetermined value, the process is continued.
  • Step e) the volume and geometry to be filled is determined.
  • This volume and geometry is subdivided into volumes and geometries of filler composition which can be applied in a single step.
  • the volume and geometry is subdivided into layers I which can be applied in a single step.
  • the total number of layers into which the volume and geometry is subdivided is an integer n, and the layer which is applied first and which therefore is the layer closest to the substrate is labeled h.
  • the subsequent layers are numbered consecutively up to layer I n .
  • the result of the calculation thus is a number of layers h to I n which can be applied to fill the dent.
  • the number of layers needed to fill said volume and geometry depends on the filler composition used, the application process, and the characteristics of the optional curing step.
  • the thickness of individual layers need not be the same.
  • the first layer(s), i.e. the layer(s) closest to the substrate can be calculated to have a higher layer thickness than the outermost layers. When such a protocol is used, faster filling of a dent can be achieved without compromising the accuracy of the dent filling process.
  • one or more layers of a filler composition are actually applied to the damaged substrate.
  • Layers h to l m of a filler composition corresponding to the volume and geometry calculated for the respective layer are applied to the damaged substrate, layers h to l m corresponding to layers which are applied subsequently without intermediate determination of the difference according to step d), and wherein m is an integer which is equal to or smaller than n.
  • m is 1.
  • the individual layers need not be of the same layer thickness.
  • Application of the filler composition is carried out by an application unit, such as a computer controlled robotic unit.
  • the application unit and the damaged substrate are moveable with respect to each other.
  • the application unit can for example be attached to a robotic arm moveable about various control axes.
  • the application unit can be fixed and the substrate is moveable about various control axes. It is also possible that both the substrate and the application unit are moveable.
  • the application unit can for example be in the form of a nozzle or a spout which suitably is connected to a reservoir of filler composition.
  • Application by dispensing or dispense jetting is preferred.
  • the filler composition is contained in a barrel and dispensed through a nozzle by applying force or pressure.
  • By this technique individual drops or continuous lines can be dispensed through a nozzle.
  • the nozzle is very close to the surface to which the filler composition is applied in order for the filler composition to make contact with that surface.
  • dispense jetting a drop of filler composition is jetted from a nozzle and travels some distance through the air before making contact with the surface.
  • Suitable filler compositions applied in the process are those materials known to the skilled person and commonly used for filling dents caused by damage, such as liquid or semi-liquid filler compositions or putties. Also so-called hot-melts can be used. Suitable filler compositions harden after application. Hardening can be caused by physical processes, i.e. cooling and/or evaporation of volatile diluents. Alternatively or additionally, hardening can be caused by chemical curing reactions. An optional curing and/or hardening step can be included in the process.
  • Curing and/or hardening can be induced by supply of thermal energy or by actinic radiation, such as UV radiation, depending on the type of filler composition used. Also two-component filler compositions which are mixed immediately prior to application and which cure at ambient temperature can be used. Curing and/or hardening can be carried out after application of individual layers of filler composition. It is also possible to cure and/or harden a plurality of layers or even all layers together at the end of the filling process.
  • the process additionally includes a sanding step.
  • Sanding of the filled dent can improve the smoothness of the surface of the filled dent. Additionally, sanding improves the smoothness of the transition between the filled dent and the surrounding undamaged area.
  • Sanding is usually carried out after all layers of filler composition have been applied and hardened and/or cured. However, it is also possible to sand individual layers. When sanding is carried out, it is possible to use a standard sanding step in order to smooth the surface. Alternatively, sanding can be used to selectively remove hardened filler composition so as to achieve a desired surface geometry.
  • the surface geometry of the damaged area is determined after an application step. Determination of the geometry after application and subsequent repetition of steps c) to g) can improve the accuracy of the process. In particular in cases where the actually applied filler layer or filler layers differ in thickness and/or geometry from the calculated filler layer(s), intermediate geometry determination is beneficial. In that case, deviations from the calculated results can be compensated for in subsequent steps. Step h)
  • steps c) to g) are repeated until the difference in geometry determined in step c) is below or equal to a predetermined value.
  • This value can be predetermined so as to achieve the required degree of matching of the original surface contours of the damaged substrate. If a high degree of matching is required, a lower predetermined difference in geometry will be selected, possibly leading to a higher number of layers to be applied. On the other hand, if a low degree of matching of the original surface is sufficient in an individual case, a higher predetermined difference will be selected as stop criterion.
  • Figure 1 is a flowchart which represents an embodiment of the process of the invention.
  • the process starts with the determination of the actual geometry of the surface of a dent, for example a dent in a body panel of a motor vehicle.
  • a computer controlled robotic unit having a laser triangulation unit attached to a robotic arm moveable about four control axes can advantageously be used.
  • the desired surface after filling of the dent is determined.
  • the desired surface geometry data can suitably be extracted from an electronic database containing CAD data of the damaged object. Calculation of the difference between the actual and the desired surface geometry is carried out by a data storage and processing unit.
  • the calculation includes subtraction of the actual surface geometry data from the desired surface geometry data and results in a volume, a geometry, and the position and orientation thereof in space, to be filled. Subsequently, it is determined whether the difference between the actual surface geometry and the desired geometry is below or equal to a predetermined value. If such is the case, the difference is sufficiently low and no further filling is required. The process is then terminated. If the difference in geometry is greater than the predetermined value, the process is continued by subdividing the volume to be filled into layers which can be applied in a single step, for example a total of 5 layers ⁇ - ⁇ to I 5 . The first two layers ⁇ - ⁇ and I2 may have a higher layer thickness than subsequent layers I 3 to I 5 .
  • the calculation is typically carried out by the data storage and processing unit under the control of a program.
  • the first layer ⁇ - ⁇ of filler composition is automatically applied to the dent.
  • Application is typically carried out by a computer controlled robotic unit having a nozzle attached to a robotic arm moveable about four control axes.
  • the nozzle is connected to a reservoir of liquid filler composition which is dispensed through the nozzle by application of pressure.
  • the filler composition is a two-component material which cures at ambient temperature.
  • the invention also relates to a system suitable for carrying out the process for automated dent filling.
  • the system comprises a) a geometry determination unit capable of determining the geometry data of a damaged surface and transmitting said geometry data, wherein the geometry determination unit and the damaged substrate are moveable with respect to each other, b) a data storage and processing unit under the control of a program, configured to receive and process geometry data and capable of controlling an application unit, and c) an application unit for applying a filler composition which is under the control of the data storage and processing unit b), wherein the application unit and the damaged substrate are moveable with respect to each other.
  • the system may be positioned on glide tracks or a gantry for movement along the substrate having a dent to be filled, such as an automobile.
  • the system generally is implemented as a computer controlled robotic unit, having arms provided with various attachments, moveable about various control axes. It is also possible to use a computer controlled robotic unit having only a single arm moveable about various control axes and having exchangeable attachments, such that specific tools as required can be affixed to the arm. Movement of the arms can be caused hydraulically or electrically, or by other suitable means known in the art.
  • the geometry determination unit is attached to such a robotic arm moveable about various control axes.
  • the geometry determination unit may be implemented as a coordinate measuring machine.
  • suitable geometry determinations units are a touch probe or a linear position sensor, such as a linear variable differential transformer (LVDT).
  • LVDT linear variable differential transformer
  • Examples of further suitable tools for geometry determination are those making use of laser triangulation, time of flight measurements, fringe projection, X-ray, photogrammetry, and interferometry.
  • the data storage and processing unit is under the control of the program.
  • the data storage and processing unit is implemented to receive and read geometry data from the geometry determination unit and optionally from other sources, such as a computer readable geometry data file.
  • the data storage and processing unit is programmed to carry out steps b) to e) of the process according to the invention.
  • the data storage and processing unit also serves as controller for directing the movement of the moveable units of the system.
  • the moveable application unit suitably is attached to a robotic arm moveable about various control axes.
  • the application unit may be implemented as a nozzle or spout connected to a reservoir of filler composition. Suitable means for controlled release of the filler composition from the nozzle or spout, such as valves and pressurizing equipment, are present as well. If filler composition of relatively low viscosity is used, the application unit may alternatively be implemented in the form of a spray gun, for example an air spray gun. Also air brush equipment may be suitable as an application unit.
  • the system also comprises a curing unit for curing the applied filler composition.
  • the curing unit and the substrate are likewise moveable with respect to each other.
  • the curing unit is attached to a robotic arm moveable about various control axes.
  • a suitable curing unit can be selected. If, for example, UV-curable filler composition is employed, the curing unit would be implemented as a source of UV radiation.
  • the curing unit may be implemented as a hot air blower or as a source of (near)infrared radiation.
  • the system may further comprise a sanding unit.
  • the sanding unit is likewise suitably attached to a robotic arm moveable about various control axes.
  • the sanding unit may be implemented as an electrically driven rotating sanding head.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Coating Apparatus (AREA)

Abstract

Cette invention concerne un procédé de remplissage automatisé d'un enfoncement dans un substrat endommagé tridimensionnel, avec une composition d'apport durcissable. L'invention concerne en outre un système permettant de mettre en œuvre de manière appropriée le procédé.
PCT/EP2008/050843 2007-01-30 2008-01-25 Remplissage automatisé d'enfoncements WO2008092799A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP07101404.7 2007-01-30
EP07101404 2007-01-30
US89927107P 2007-02-02 2007-02-02
US60/899,271 2007-02-02

Publications (1)

Publication Number Publication Date
WO2008092799A1 true WO2008092799A1 (fr) 2008-08-07

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011018199A1 (fr) * 2009-08-10 2011-02-17 Dürr Systems GmbH Procédé et dispositif pour lisser une surface d'élément, notamment de grandes structures

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4416068A (en) * 1980-12-11 1983-11-22 Infrarodteknik Ab Apparatus for surface treatment of objects
US6365221B1 (en) * 1999-11-23 2002-04-02 Visions East, Inc. Computer controlled method and apparatus for fairing and painting of marine vessel surfaces
US6398870B1 (en) * 1999-05-25 2002-06-04 Chuo Electronic Measurement Co., Ltd. Coating defect detecting and marking system
EP1473095A1 (fr) * 1998-11-05 2004-11-03 Tateo Uegaki Procédé de calculation du travail nécessaire à réparer un panneau de carrosserie d'un véhicule

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4416068A (en) * 1980-12-11 1983-11-22 Infrarodteknik Ab Apparatus for surface treatment of objects
EP1473095A1 (fr) * 1998-11-05 2004-11-03 Tateo Uegaki Procédé de calculation du travail nécessaire à réparer un panneau de carrosserie d'un véhicule
US6398870B1 (en) * 1999-05-25 2002-06-04 Chuo Electronic Measurement Co., Ltd. Coating defect detecting and marking system
US6365221B1 (en) * 1999-11-23 2002-04-02 Visions East, Inc. Computer controlled method and apparatus for fairing and painting of marine vessel surfaces

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011018199A1 (fr) * 2009-08-10 2011-02-17 Dürr Systems GmbH Procédé et dispositif pour lisser une surface d'élément, notamment de grandes structures
CN102481596A (zh) * 2009-08-10 2012-05-30 杜尔系统有限责任公司 用于平滑部件的，尤其是大结构的表面的方法和装置

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