First time quality is not accessible in current high tolerance, large complex robotic coatings applications within the defense and aerospace industries, leading to excessive manual rework, re-programming, and increased product lead time. Currently, there are limited, viable, solutions for coating and finishing of complex geometry parts with closed-loop metrology feedback with agile robotic path planning. The challenge is mapping complex surface geometries (for example: overhangs, vertices, and holes) to ensure surface coverage without overspray onto other surfaces in high-mix, high-variation parts. This overspray causes costly robot programming, commissioning and manual rework when automation fails to ensure quality. Defects include non-conformance coating thickness, orange peel, and runs.
When this happens, additional rework may include manual sanding, which can increase production times by one full day of work or in some cases two full weeks. This work has a high risk of causing damage to the underlying structure and the manual process typically requires worker exposure to hazardous and/or ergonomically challenging positions for extended periods of time.
By pursuing a fully autonomous closed-loop system, this project team addressed the concerns of quality, precision, and efficiency in potentially harmful, wasteful, and time-consuming painting and sanding procedures.