WO2021086880A1 - Système et procédé d'application d'isolation à un produit - Google Patents

Système et procédé d'application d'isolation à un produit Download PDF

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Publication number
WO2021086880A1
WO2021086880A1 PCT/US2020/057603 US2020057603W WO2021086880A1 WO 2021086880 A1 WO2021086880 A1 WO 2021086880A1 US 2020057603 W US2020057603 W US 2020057603W WO 2021086880 A1 WO2021086880 A1 WO 2021086880A1
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WO
WIPO (PCT)
Prior art keywords
insulation
robotic system
charges
spray
panels
Prior art date
Application number
PCT/US2020/057603
Other languages
English (en)
Inventor
Emily Jean VAN COURT
Mary H. POMA
Rohit Ghosh
Robert Armstrong
Tomasz CWIK
Original Assignee
Basf Se
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 Basf Se filed Critical Basf Se
Publication of WO2021086880A1 publication Critical patent/WO2021086880A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
    • B05B13/0431—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with spray heads moved by robots or articulated arms, e.g. for applying liquid or other fluent material to 3D-surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B15/00—Details of spraying plant or spraying apparatus not otherwise provided for; Accessories
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063—Operations research, analysis or management
    • G06Q10/0631—Resource planning, allocation, distributing or scheduling for enterprises or organisations
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
    • G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders

Definitions

  • the present application is generally related to a system for applying insulation to a product.
  • insulated products are manufactured manually by applying insulation material to a product by manufacturing personnel.
  • Manual production of insulated products may be challenging, labor-intensive, time consuming and expensive. Additionally, manual production may pose a health risk for the manufacturing personnel, for example, with regard to the materials used, which may also require a protective equipment.
  • a system and method for applying insulation to a part may include one or more robotic cells that apply insulation material on a product.
  • the insulation may be applied by spraying, pouring, brushing or other known method.
  • the product to be sprayed may be a panel, such as construction panel, automotive panel, or other panel and may be either 2-dimensional or 3-dimensional in nature.
  • the system may generate a queue of product profiles including, for example, spray paths based on entered orders for the construction panels. The sequence of the queue may be adjusted in response to order criteria and/or cell setup characteristics. The system may also calculate the cost for applying the insulation to the panel.
  • Insulated products can be used in many ways, for example, to achieve thermal insulation, sound insulation or the like.
  • the field of application of such insulated products may extend to applications in numerous industries, such as construction industry, automotive industry, packaging industry etc.
  • the insulated products may be used as an interior trim, as an exterior wall cladding, as a construction member, as packaging material, or the like, and are usable in a wide range of industries.
  • FIG. 1 is a schematic diagram of a robotic system for spraying insulation on construction panels
  • FIG. 2 is a schematic diagram illustrating a sequence of processing for a robotic cell
  • FIG. 3 is a graphical illustration showing the adjusting of a sequence based on order criteria or set-up characteristics
  • FIG. 4 is a schematic diagram of a system of applying insulation to products such as construction panels.
  • FIG. 5 is a flow chart illustrating a method for applying insulation to a product.
  • FIG. 1. is a schematic diagram of a robotic system for applying insulation to construction panels.
  • the system 110 includes a robotic cell 112 that is configured to robotically apply (e.g. spray) insulation onto a product, such as a construction panel 116.
  • the construction panel 116 may be formed of wood, polymer, or other construction material and may be part of a modular assembly such as a mobile home or other modular construction.
  • the product may be an automotive or other panel.
  • the insulation may be a foam that is sprayed as one or more liquids that are combined together and form a foam on the target product
  • the robotic cell 112 may include a robotic arm 114 that may include a spray nozzle 115 configured to spray insulation onto the construction panel 116.
  • the robotic arm 114 may include a spray nozzle 115 configured to spray insulation onto the construction panel 116.
  • the nozzle 115 may move the nozzle 115 relative to the panel 116 along a spray path to coat the construction panel 116 with insulation in appropriate areas as defined by the spray path.
  • the panel 116 may be moved relative to the nozzel 115 or the nozzel 115 may be moved relative to the panell 16.
  • the construction panel 116 may be mounted on a fixture 118.
  • the fixture 118 may fix the position of the construction panel 116 relative to the robot arm 114.
  • a gantry 120 may be attached to fixture 118 to move the fixture 118 and the construction panel 116 relative to the robot arm 114. This would allow the robot arm to cover a larger panel than would be possible with simply the robot arm itself based on the robot arm reach.
  • the robot arm 114 may be located on a gantry extending the reach of the robot arm 114, which may be done in addition or alternatively to the gantry 120 attached to the fixture 118.
  • the insulation applied by the robot arm 114 may be in the form of a spray or foam. Insulation may be a single material applied by the robot arm 114 or may include multiple materials that are combined as the robot arm 114 applies the insulation to the construction panel 116. For example, a first material 122 may be combined with a second material 124 to generate an insulation foam as the materials are sprayed through the nozzle
  • a controller 126 may monitor the process of the robot arm 114 applying the insulation to the construction panel 116.
  • the process controller 126 may be in communication with all elements of the robotic cell 112. For example, the controller 126 may monitor the amount of the first material 122 and the amount of the second material 124 through sensors attached to the containers for each of the materials. [0015] In addition, the controller 126 may monitor the motion and characteristics of the robot arm 114 to track the amount of material consumed, as well as, the area covered on one or more of the construction panels 116. Further, the controller 126 may be in communication with the gantry 120 or the fixture 118 to track a number and a type of construction panel 116 that are processed by the system.
  • All of the information that is tracked and generated by the controller 126 may be stored in a local datastore 128 (e.g. such as a database or other data container) and may also be communicated through one or more networks 130 to a remote server 132.
  • the remote server 132 may be located at a different premises (e.g. different property and/or building) than the robot cell 112.
  • the one or more networks 130 may include the internet or other wide area network.
  • the remote server 132 may store any of the information received in a datastore 134. Further, the server 132 may provide a remote interface for administrative tasks such as order entry, order sequencing, order shipping, inventory management, and billing or invoicing.
  • the server 126 or remote server 132 may determine the cost for each panel by tracking the amount of material consumed, the energy used and, the maintenance associated with each product or spray path.
  • the server 126 or remote server 132 may also generate an invoice and calculate charges for the invoice to the manufacturer of the panels and/or the end customer in response to the cost, as well as, other factors such as order criteria, set-up characteristics, and maintenance data.
  • the invoice may be an electronic payment request or electronic account debit (although more traditional invoices may also be triggered).
  • the costs and/or charges may be updated periodically (e.g. on a monthly or weekly basis) and may be updated according to an analysis (e.g. a statistical analysis) of the panels being sprayed.
  • the charges may be calculated based on the type of insulation, the spray profile (e.g. a board foot measurement according to the corresponding spray profile), an amount of material used / remaining (e.g. from an inventory management controller), a type of material sprayed, a type of nozzle used, or a type of fixture used.
  • the spray profile e.g. a board foot measurement according to the corresponding spray profile
  • an amount of material used / remaining e.g. from an inventory management controller
  • a type of material sprayed e.g. a type of nozzle used, or a type of fixture used.
  • a billing controller may receive from a process controller the amount of material used and the amount of board feet sprayed.
  • the overhead may include maintenance, energy and/or capital costs.
  • the charges may be calculated on a time period (e.g. monthly, weekly), panel or board foot basis.
  • a different margin rate may be charged for material and overhead.
  • the margin rate may be different for each material and, likewise, the margin rate may be different for each component of overhead.
  • the manufacturer of the panels e.g. a panelizer
  • the manufacturer of the panels may own the cells and be charged for the material based on board feet of insulation sprayed according to the spray paths of the part profiles.
  • the manufacturer may allow a supplier to provide the cells in their manufacturing facility and the cost of the capital equipment may be incorporated into the price per board foot, per linear foot, per spray profile, or per product.
  • the required technical knowledge of selecting component pieces to build a complete robotic cell by a panelizer in their plant may be reduced.
  • the required technical knowledge is also decreased regarding ventilation rates given cell layout and volume for a spray room.
  • the technical knowledge regarding dwell time of product following spray, depending on substrate, temporary storage, and transport may be decreased.
  • the software development to integrate purchased hardware systems may also be reduced when compared to internal system development.
  • the panelizer purchased components individually the panelizer would be required to coordinate system components and develop significant additional back-of-house systems.
  • the cloud software embedded in the system as described may provide new pricing models where the customer pays for a “customer benefit” as opposed to a more typical price per kg of raw materials.
  • the customer pays for a finished product (calibrated to a specific R-value), for example, measured in dollars per board foot, eliminating costs associated with waste.
  • the software may be able to accurately measure the material usage rate and charge the customer for the product with insulation applied.
  • This implementation may provide a bundled service model for the customer where, for example, the customer pays for a single service of applying the insulation rather than the materials and labor separately.
  • one or two points of contact e.g.
  • FIG. 2 is a schematic diagram illustrating a sequence of processing for a robotic cell.
  • a first sequence is denoted by reference number 200.
  • the sequence includes a first panel 202, a second panel 204, a third panel 206, a fourth panel 208, and a fifth panel 210.
  • the sequence many be determined by the chronological order in which each panel is entered into the system. As such, the order of the panels may be somewhat random which can lead to inefficient processing of the panels through the robotic cell.
  • Either the server within a cell or a remote server may analyze and adjust the sequencing of panels to provide a more efficient throughput of construction panels through the manufacturing system.
  • the sequence of the panels may be adjusted based on various factors including for example, order criteria and/or set-up characteristics.
  • the order criteria may include, for example, the requested timing of the order, the pricing of the order, any premium paid for advancing the order faster, as well as the components (e.g., types of panels) that belong to each order.
  • the set-up characteristics may include the materials that are loaded and/or attached to the robotics arm 114. The set-up characteristics may also include the amount of each material remaining, the type of nozzle used, the fixture that is attached as well as any fixture options, the panels loaded, the down timing of the robotic arm or system as a whole, as well as, the maintenance schedule of the robotic arm or system as a whole. [0023] An adjusted sequence is illustrated with regard to reference numeral 212.
  • the sequence has been changed so that all of the same type of panel may be processed together one after another in a group as denoted by reference number 220.
  • the sequence has been adjusted to process panel 202 then panel 208 followed by panel 210. Accordingly, 220 is processed first, then panel 204 and panel 206 may be processed afterward. In some systems this may reduce change over inefficiencies and costs.
  • FIG. 3 is another graphical illustration showing the adjusting of a sequence based on order criteria or set-up characteristics.
  • Sequence 300 may be the original sequence analyzed by the controller. The sequence may include in order, panel 302, panel 304, panel 306, panel 308, and panel 310. A revised sequence may be illustrated with regard to reference numeral 312.
  • the panels may be grouped with regard to a certain order by a particular customer or a certain module that is comprised of multiple panels that fit together but may be later assembled.
  • a grouping 330 due to a particular customer order or that may form a single module is shown.
  • the sequence 312 is adjusted in that panel 308 and panel 310 are moved forward in the sequence to be processed directly after panel 301.
  • panels 302, 308, and 310 may form a particular customer order or an assembly module.
  • Efficiency may dictate the group 330 being processing together and for example, first before other panels such as panel 304 and panel 306 to meet delivery deadlines or inventory constraints.
  • the sequence 312 has been adjusted in the order of panel 302, panel 308, panel 310, panel 304, and panel 306 in order.
  • FIG. 4 is a schematic diagram of a system of applying insulation to products such as construction panels.
  • the system 410 includes a process controller 412, a queue of product profiles 414 and at least one robotic cell for example, robotic cell 416 and robotic cell 418.
  • the process controller 412 may correspond to the server 126 located locally to the robotic cells or may correspond to the remote server 132 that was located remote from the robot cell, for example, at a different premises from the robotic cells.
  • the queue of product profiles 414 may include spray paths as discussed previously with regard to FIG. 1 as well as other information that may be relevant to the processing within the system 410.
  • Each robotic cell 416 and 418 may correspond to a robotic cell as depicted with regard to robotic cell 112 in FIG. 1.
  • the system 410 may include a datastore 424 which more correspond to datastores 134 or 128 in FIG. 1.
  • the system 410 includes an order controller 420, a shipping controller 421, a billing controller 422, a maintenance management controller 442, and an inventory management controller 440. Each of these controllers may correspond to either server 126 or server 132 in FIG. 1 or may correspond to a separate controller and/or independent hardware not depicted in FIG. 1.
  • the order controller 420 may receive an order from a customer or distributor through an user interface for example, an external web interface, or from an internal order interface controlled by the company implementing the system 410.
  • the order controller 420 may be in communication with the datastore 424 and store a record for each order for example, depicted by order 426 and order 428.
  • the order controller 420 may be in communication with the shipping controller 421 to receive information about the time that would be required to ship the completed order to the customer site as well as other orders and how the other orders affect the timing of the processing as it relates to the requested timing for each order that is entered to the order controller 420.
  • Each record 426 and 428 may include order criteria for example, the timing of the order, the pricing of the order, any premium paid for expediting the order, as well as the components included in the order that will need to be shipped.
  • the queue 414 will be populated with product profiles (for example, Al-An). Further, the sequence of the profiles may be determined based on for example, order grouping, which may be denoted as group 430 for order 426 and grouping 432 for order 428. However, the grouping and sequence may be changed by the process controller 412 based on various factors including, for example, order criteria or the set-up characteristics of each cell 416 and 418. The process controller 412 may also determine which profiles are sent to which robotic cells 416, 418 based on order criteria and/or set-up characteristics. This could allow all of one type of panel to be allocated to a particular cell or, for example, all of one order could be allocated to a particular cell based on the most efficient set-up for the pending orders and profiles in the queue 414.
  • the process controller 412 may be in communication with an inventory management controller 440 and a maintenance controller 442.
  • the process controller may determine which product profiles are sent to which cell 416, 418 based on the inventory management controller 440 which may monitor and determine how much of each material is available at each cell.
  • the inventory management controller 440 may initiate orders for additional material for example, from a supplier company that may be shipped to the robotic cell in response to the order criteria, the profiles in the queue 414 as well as set-up characteristics of each cell 416 and cell 418.
  • the process controller 412 may determine which product profiles are sent to which cell 416, 418 based on the maintenance controller 442 which may monitor and determine when maintenance or replacement parts are required. Further, the maintenance controller 442 may initiate orders for service or replacement parts, for example, from a supplier or maintenance company that is responsible for repair of the robotic cell in response to the order criteria, the profiles in the queue 414 as well as set-up characteristics of each cell 416, 418. Accordingly, the need for maintenance may be balanced with production constraints.
  • the processor controller 412 may also be in communication with the billing controller 422.
  • the billing controller may generate invoices to the customers in response to the order server 420 and also in response to the process controller 412 which may take into account the spray paths in the queue 414 for each panel and, therefore, may calculate charges based on a formula that may include multiple factors.
  • the billing may be based on board feet of insulation spray.
  • other models may include for example, a factor that includes maintenance, the amount of each material utilized, any of the order criteria and any of the set-up characteristics.
  • the calculation of charges may include any of the elements as described throughout this application.
  • any one or more of the process controller 412, the inventory management controller 440, the maintenance controller 442, the robot cells 416 and 418, and the billing controller 422 may be owned and operated by a material supplier allowing a service billing model as described elsewhere in this application.
  • an invoice may be generated by the billing controller 422 indicating charges in response to the cost for spraying insulation on the panel, set-up characteristics of the robotic system, a number of board feet of insulation sprayed.
  • the robotic system may be owned and/or maintained by a third party (for example a material supplier) providing the panelizer a bundled service including material, equipment, and maintenance, without a substantial capital investment.
  • Figure 5 is a flow chart illustrating a method for applying insulation to a product.
  • the system receives input such as an order or a file (e.g. a CAD file) with a list of panels to be manufactured.
  • the input may be received through an external source like a customer or a distributor, for example through a web interface.
  • the order may include order criteria as noted elsewhere in the specification.
  • the system may then analyze the queue of spray profiles.
  • the set-up characteristics of one or more robotic cells is determined.
  • the order criteria may be determined.
  • the sequence and/or cell for the spray profiles may be determined based on the set-up characteristics of one or more cells.
  • the insulation may be applied, for example to the construction panels as described elsewhere in this specification. If the queue is not empty (e.g. there are more panels / spray profiles in the queue) then the method proceeds to block 524.
  • inventory management is performed. For example, the amount of each material remaining is monitored. If any of the material needs to be reordered (e.g. it falls below a given threshold level) then an order is initiated with a supplier to ship additional material, for example, through an electronic interface.
  • maintenance of the system is monitored. For example, the times or cycles are monitored relative to a preventative maintenance schedule. As such, the sequence of panel may be adjusted in response to minimize the impact of maintenance on the required deliver times.
  • the sequence of the panels and cell assignments may then be adjusted in block 520, prior to further panel processing. If the queue is complete or in parallel with further processing, billing may be determined in block 528 in response to the order criteria, product profile, and/or set-up characteristics. Further, the charges may be calculated based on the factors and according to the methodology as presented elsewhere in this application.
  • the methods, devices, processing, and logic described above may be implemented in many different ways and in many different combinations of hardware and software.
  • all or parts of the implementations may be circuitry or controllers that include an instruction processor, such as a Central Processing Unit (CPU), microcontroller, or a microprocessor; an Application Specific Integrated Circuit (ASIC), Programmable Logic Device (PLD), or Field Programmable Gate Array (FPGA); or circuitry that includes discrete logic or other circuit components, including analog circuit components, digital circuit components or both; or any combination thereof.
  • the circuitry may include discrete interconnected hardware components and/or may be combined on a single integrated circuit die, distributed among multiple integrated circuit dies, or implemented in a Multiple Chip Module (MCM) of multiple integrated circuit dies in a common package, as examples.
  • MCM Multiple Chip Module
  • the circuitry may further include or access instructions for execution by the circuitry.
  • the instructions may be stored in a tangible storage medium that is other than a transitory signal, such as a flash memory, a Random Access Memory (RAM), a Read Only Memory (ROM), an Erasable Programmable Read Only Memory (EPROM); or on a magnetic or optical disc, such as a Compact Disc Read Only Memory (CDROM), Hard Disk Drive (HDD), or other magnetic or optical disk; or in or on another machine-readable medium.
  • a product such as a computer program product, may include a storage medium and instructions stored in or on the medium, and the instructions when executed by the circuitry in a device may cause the device to implement any of the processing described above or illustrated in the drawings.
  • the implementations may be distributed as circuitry among multiple system components, such as among multiple processors and memories, optionally including multiple distributed processing systems.
  • Parameters, databases, and other data structures may be separately stored and managed, may be incorporated into a single memory or database, may be logically and physically organized in many different ways, and may be implemented in many different ways, including as data structures such as linked lists, hash tables, arrays, records, objects, or implicit storage mechanisms.
  • Programs may be parts (e.g., subroutines) of a single program, separate programs, distributed across several memories and processors, or implemented in many different ways, such as in a library, such as a shared library (e.g., a Dynamic Link Library (DLL)).
  • the DLL may store instructions that perform any of the processing described above or illustrated in the drawings, when executed by the circuitry.

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Abstract

L'invention concerne un système et un procédé pour appliquer une isolation à une pièce. Le système peut comprendre une ou plusieurs cellules robotiques qui appliquent un matériau isolant sur un produit. Le produit peut être un produit et une file d'attente de profils de produit comprenant des trajets de pulvérisation qui peut être générée sur la base de commandes entrées pour le produit. La séquence de la file d'attente peut être ajustée en réponse à des critères de commande et/ou à des caractéristiques de configuration de cellule.
PCT/US2020/057603 2019-11-01 2020-10-28 Système et procédé d'application d'isolation à un produit WO2021086880A1 (fr)

Applications Claiming Priority (2)

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US201962929305P 2019-11-01 2019-11-01
US62/929,305 2019-11-01

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150375390A1 (en) * 2014-03-06 2015-12-31 Encore Automation Robotic system for applying surface finishes to large objects
US20160121486A1 (en) * 2013-05-23 2016-05-05 Q-Bot Limited Method of Covering a Surface of a Building and Robot Therefor
GB2539661A (en) * 2015-06-22 2016-12-28 Q-Bot Ltd Robotic Vehicle
US20180283019A1 (en) * 2017-03-31 2018-10-04 Canvas Construction, Inc. Automated drywalling system and method
US20190076868A1 (en) * 2015-06-17 2019-03-14 Integrated Construction Enterprises, Inc. Autonomous painting systems and related methods

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160121486A1 (en) * 2013-05-23 2016-05-05 Q-Bot Limited Method of Covering a Surface of a Building and Robot Therefor
US20150375390A1 (en) * 2014-03-06 2015-12-31 Encore Automation Robotic system for applying surface finishes to large objects
US20190076868A1 (en) * 2015-06-17 2019-03-14 Integrated Construction Enterprises, Inc. Autonomous painting systems and related methods
GB2539661A (en) * 2015-06-22 2016-12-28 Q-Bot Ltd Robotic Vehicle
US20180283019A1 (en) * 2017-03-31 2018-10-04 Canvas Construction, Inc. Automated drywalling system and method

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