Patent Publication Number: US-2004057708-A1

Title: Flexible height paint curing apparatus and method

Description:
BACKGROUND OF THE INVENTION  
       [0001] The present technique relates generally to finishing systems and, more particularly, to industrial finish curing systems. In specific, a system and method is provided for vertically adapting an adjustable arm assembly to position a mounted curing device in a desired curing position based on the height of a particular target object, such as differently sized vehicles.  
       [0002] Finish coatings, such as paint, are often applied to a product and subsequently cured via heating devices. In many finishing systems, the product is placed in a curing room, where heat is flowed through the room to dry the finish coatings that were applied to the product. Although such curing rooms may be practical for large-scale manufacturing, the typical small-scale facility may not have the space or resources to use such curing rooms. For example, automobile repair shops may not have sufficient space or financial resources to set up a curing room.  
       [0003] Accordingly, a technique is needed for finishing and curing a variety of products without requiring a special finishing or curing room.  
       SUMMARY OF THE INVENTION  
       [0004] The present technique provides a system and method for finishing and curing a desired material applied to a surface of a target object, such as a vehicle. An adjustable arm assembly is used to position a curing device, such as a radiative curing mechanism, adjacent the surface having the desired material. The adjustable arm assembly has an arm structure, which is rotatable between minimum and maximum vertical positions. At a head of the arm structure, the adjustable arm assembly has an adjustable height mechanism to adapt the vertical range of the arm structure to a particular target object, such as a large-sized or small-sized object. The head may support any suitable finishing or curing device, such as an infrared lamp. The adjustable height mechanism may have a reversible coupling assembly, mutually exclusive high and low couplings, a pivotal offset coupling, a rail assembly, or any other suitable coupling having at least two different height options. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0005] The foregoing and other advantages and features of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:  
     [0006]FIG. 1 is a diagram illustrating an exemplary finishing system of the present technique;  
     [0007]FIG. 2 is a diagram illustrating an exemplary finish curing system of the present technique;  
     [0008]FIG. 3 is a flow chart illustrating an exemplary finishing and curing process of the system illustrated in FIGS. 1 and 2;  
     [0009]FIG. 4 is a perspective view of an exemplary adjustable arm assembly, curing device, and adjustable height mechanism of the finish curing system illustrated in FIG. 2;  
     [0010]FIG. 5 is a perspective view of an alternative embodiment of the finish curing system illustrated in FIG. 4; and FIGS.  6 - 9  are side views illustrating different height configurations of the finish curing system illustrated in FIGS. 4 and 5. 
    
    
     DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS  
     [0011] The present technique provides a unique arm mounted curing device, which may be used to apply or cure a desired material applied to a surface of a variety of differently sized products. For example, instead of placing the product in a heated room, the present technique directly cures the desired material by positioning a curing device (e.g., an infrared heating lamp) directly adjacent the desired material. Moreover, the present technique uses a standard-sized rotatable arm with a height-adjustable end mechanism to accommodate the differently sized products. In automotive finishing applications, the height-adjustable end mechanism may have high and low offset positions to accommodate large-sized and small-sized vehicles. Accordingly, the height-adjustable end mechanism adapts the standard-sized rotatable arm to the particular height/size of the target product. The height-adjustable end mechanism also may be used to adapt the vertical range of the standard-sized rotatable arm to the particular working environment, such as a lift mounted position, a pallet mounted position, and so forth.  
     [0012]FIG. 1 is a flow chart illustrating an exemplary finishing system  10 , which comprises a spray coating device  12  for applying a desired coating to a target object  14 . For example, the spray coating device  12  may comprise an air atomizer, a rotary atomizer, an electrostatic atomizer, or any other suitable spray formation mechanism. The spray coating device  12  may be coupled to a variety of supply and control systems, such as a material supply  16  (e.g., a fluid or powder), an air supply  18 , and a control system  20 . The control system  20  facilitates control of the material and air supplies  16  and  18  and ensures that the spray coating device  12  provides an acceptable quality spray coating on the target object  14 . For example, the control system  20  may include an automation system  22 , a positioning system  24 , a material supply controller  26 , an air supply controller  28 , a computer system  30 , and a user interface  32 . The control system  20  also may be coupled to a positioning system  34 , which facilitates movement of the target object  14  relative to the spray coating device  12 . For example, the positioning system  34  may comprise an assembly line, a hydraulic lift, a robotic arm, and a variety of other positioning mechanisms controlled by the control system  20 . Accordingly, the finishing system  10  may provide a computer-controlled spray pattern across the surface of the target object  14 .  
     [0013] The finishing system  10  of FIG. 1 is applicable to a wide variety of applications, fluid coating materials, powder coating materials, target objects, and types/configurations of the spray coating device  12 . For example, a user may select a desired object  36  from a variety of different objects  38 , such as different material and product types. The user also may select a desired material  40  from a plurality of different materials  42 , which may include different coating types, colors, textures, and characteristics for a variety of materials such as metal and wood. For example, the desired material  40  may comprise a powder coating material, a fluid coating material (e.g., a paint), a filler material (e.g., body filler), and so forth. In one exemplary embodiment, the finishing system  10  may be incorporated into a vehicle assembly line or a vehicle repair facility.  
     [0014]FIG. 2 is a flow chart illustrating an exemplary finish curing system  50 , which comprises a curing device  52  for curing a desired material applied to the target object  14 . For example, the curing device  52  may comprise one or more heating devices (e.g., radiative heating mechanisms, such as infrared lamps), drying devices, or other suitable curing mechanisms. In this exemplary embodiment, the curing device  52  is coupled to an adjustable arm assembly  54 , which positions the curing device  52  in a desired curing position relative to the target object  14 . The adjustable arm assembly  54  also has an adjustable height mechanism  56 , which adapts the vertical range of the adjustable arm assembly  54  to the geometry of the particular target object  14 . For example, the adjustable height mechanism  56  is movable between high and low positions to accommodate target objects (e.g., cars, trucks, boats, airplanes, or other vehicles) ranging from large-sized to small-sized.  
     [0015] The finish curing system  50  also may include a variety of positioning and control systems (e.g., manual or automatic), such as control system  58  and object positioning system  60 . The control system  58  ensures that the desired material is efficiently and optimally cured onto the target object  14 . For example, the control system  58  may include an automation system  62 , an object positioning controller  64 , a curing/heating controller  66 , an arm positioning controller  68 , a computer system  70 , and a user interface  72 . The control system  58  also may be coupled to the object positioning system  60 , which facilitates movement of the target object  14  relative to the curing device  52 . For example, the object positioning system  60  may comprise a manual positioning mechanism, an assembly line, a hydraulic lift, a robotic arm, and a variety of other  15  positioning mechanisms operated by the control system  58 . Accordingly, the finish curing system  50  may automatically cure/dry the desired material to provide a cured surface material with the desired characteristics. However, the present technique also may operate without any automation controls and the target object may be stationary, such as a damaged vehicle in a repair shop. Accordingly, the present technique may produce a uniquely cured powder coating, fluid spray coating, filler material, adhesively-backed decal, or any other such material applied to the surface.  
     [0016]FIG. 3 is a flow chart of an exemplary finishing process  100  for applying and curing a desired material to the target object  14 . As discussed above, the desired material may be a powder coating material, a fluid coating material, a filler material, or any other suitable surface applied material, including paints, varnishes, clear coats fillers, top coats, and so forth. As illustrated, the process  100  proceeds by identifying the target object  14  for application of the desired material (block  102 ). The process  100  then proceeds by selecting the desired material  40  for application to a surface of the target object  14  (block  104 ). A user may then proceed to configure the application device, the identified target object  14 , and desired material (block  106 ). If the device is a spraying device, the process  100  then proceeds to create an atomized spray of the selected fluid or powder. The user may then apply the desired material over the desired surface of the target object  14  (block  110 ). The process  100  then proceeds to cure/dry the desired material that was applied over the desired surface (block  112 ). If the user desired an additional application of the desired material at query block  114 , then the process  100  proceeds through blocks  110  and  112  to provide another application of the desired material. If the user does not desire an additional material application at query block  114 , then the process  100  proceeds to query block  116  to determine whether the user desires a new material application. If a new material application is desired at query block  116 , then the process  100  proceeds through blocks  104 - 114  using a new selected material. If the user does not desire a new material application at query block  116 , then the process  100  is finished at block  118 .  
     [0017] As described in further detail below, the foregoing systems  10  and  50  and the finishing process  100  may utilize a variety of positioning assemblies, such as the adjustable arm assembly  54 . FIG. 4 is a perspective view of an exemplary embodiment of the finish curing system  50  having the curing device  52  coupled to the adjustable arm assembly  54  via the adjustable height mechanism  56 . As illustrated, the adjustable arm assembly  54  comprises an arm structure  120  rotatably coupled to an arm support  122  via a pivot joint  124 .  
     [0018] Although the arm structure  120  is illustrated as a single straight arm, the adjustable arm assembly  54  may have a multi-section arm and any suitable straight or curved geometry. The arm structure  120  also may have a variety of positioning control linkages to facilitate a desired vertical, lateral, and angular position. For example, the illustrated adjustable arm assembly  54  has an arm positioning linkage  126  extending between the arm support  122  and the arm structure  120 , such that the arm structure  120  may be moved vertically in a range extending between minimum and maximum vertical positions. The adjustable arm assembly  54  also may have a variety of rotation-inducing mechanisms coupled to the arm structure  120 , such that the arm structure  120  can be positioned in a desired angular position. In the illustrated embodiment, the adjustable arm assembly  54  has an adjustable end structure  128  rotatably coupled to the arm structure  120  at a pivot joint  130 . At an adjacent pivot joint  132 , the adjustable end structure  128  is rotatably coupled to an end positioning linkage  134  that is rotatably coupled to the arm support  122  via a pivot joint  136 . As described with reference to FIG. 2, each of the foregoing linkages may comprises a variety of manual or automatic motion-inducing mechanisms, such as a hydraulic mechanism, a pneumatic mechanism, a geared mechanism, a motorized mechanism, a cable and pulley mechanism, or any other suitable mechanism.  
     [0019] The illustrated arm support  122  includes a vertical support  138  extending from a base structure  140 , which has a plurality of wheels  142 . However, the arm support  122  may comprise any suitable fixed or movable structure depending on the particular application. For example, the arm support  122  may be bolted or generally secured to a wall, a floor, a vehicle, a trailer, or any other suitable vertical, horizontal, or angled mounting structure. The arm support  122  also may have a manual or automatic positioning system, such as a rotational or linear positioning system to move the arm support  122  adjacent the target object  14 . Accordingly, the adjustable arm assembly  54  can position the curing device  52  in a desired curing position relative to the target object  14 .  
     [0020] The curing device  52 , as illustrated in FIG. 4, includes a pair of heating/drying devices  144  and  146 . The heating/drying devices  144  and  146  can have any suitable drying mechanism, such as conductive, convective, and radiative heat transfer mechanisms, which may cure a fluid coating, a powder coating, a filler, an adhesive, and so forth. For example, the heating/drying device  144  and  146  may comprise a fuel combustion heater, an electrical resistance heater, or an optical/light radiation heating mechanism, such as an infrared lamp. In this exemplary embodiment, the heating/drying devices  144  and  146  have infrared mechanisms. The heating/drying devices  144  and  146  are mounted to a head structure  148 , which is coupled to the adjustable end structure  128  via the adjustable height mechanism  56 . The illustrated head structure  148  has a fork-shaped extension  150  rotatably coupled to an E-shaped support  152  via a pivot joint  154 . However, any suitable multi-section or integral support structure or yoke is within the scope of the present technique. The head structure  148  also may have a manual or automatic positioning system to pivot the E-shaped support  152  about the pivot joint  154 .  
     [0021] At the adjustable end structure  128 , the adjustable height mechanism  56  of FIG. 4 provides a high mounting position  156  and a low mounting position  158  for the head structure  148 . In this exemplary embodiment, the head structure  148  is interchangeably and selectively mountable at either one of the high and low mounting positions  156  and  158  via a fastener  160 . For example, the high and low mounting positions  156  and  158  may comprise female threads that can receive male threads of the fastener  160 . The high and low mounting positions  156  and  158  also may include mechanical latches, hooks, or other releasable and interchangeable mount structures. The illustrated fastener  160  also may operate as a pivot joint for rotating the head structure  148  relative to the arm structure  120 . A manual or automatic positioning system may then be coupled to the foregoing pivot joint to facilitate rotation of the head structure  148 .  
     [0022] Alternatively, the adjustable height mechanism  56  may have a single mounting mechanism, such as an offset mounting structure, while the adjustable height mechanism  56  is reversibly and interchangeably mountable to the adjustable end structure  128 . For example, the adjustable height mechanism  56  may be released, swiveled about a pivot joint, and then resecured to the adjustable end structure  128 . The adjustable height mechanism  56  also may be detached, rotated 180 degrees, and then reattached to the adjustable end structure  128 . Accordingly, by reversibly mounting the adjustable height mechanism  56  to the adjustable height mechanism  56 , the head structure  148  can be mounted in a higher or lower position similar to those of the high and low mounting positions  156  and  158 .  
     [0023] In either the multi-mount or single-mount configuration of the adjustable height mechanism  56 , the height variance between the various mounting mechanisms may be selected to extend the adjustable arm assembly  54  beyond its minimum and maximum height. For example, if the prospective target objects  14  have a variety of dimensions, such as large-sized and small-sized, then the foregoing height variance can be tailored to the different heights of these differently sized target objects. In an automotive application, the height variance may be chosen to accommodate vehicles ranging from small cars to large trucks. The height variance also may accommodate different object positions, such as lift-mounted, trailer mounted, assembly line mounted, pallet-mounted, and so forth.  
     [0024] In a further alternative embodiment, the adjustable height mechanism  56  may comprise a linear positioning mechanism  162 , as illustrated in FIG. 5. The linear positioning mechanism  162  may have a variety of manual or automatic motion-inducing mechanisms, such as a hydraulic mechanism, a pneumatic mechanism, a geared mechanism, a motorized mechanism, a cable and pulley mechanism, a rail and carrier mechanism, or any other suitable manually or automatically movable mechanism. Again, the vertical range of the linear positioning mechanism  162  may be tailored to the different heights and sizes of the prospective target objects  14 .  
     [0025] In operation, the finish curing system  50  can position the head structure  148  and mounted curing device  52  adjacent low and high surfaces of various different target objects  14 , such as small and large-sized vehicles. At each of these positions, the heating/drying devices  144  and  146  operate to cure the desired material applied to the surface of the target object  14 . Again, the desired material may be a paint, a wax, a filler (e.g., body filler), a fluid or powder sprayed coating material, a brush applied coating material, a clear coat material, or any other suitable surface application materials. FIGS.  6 - 9  are side views illustrating exemplary configurations of the finish curing system  50  utilizing the adjustable height mechanism  56 .  
     [0026] As illustrated in FIGS. 6 and 7, the system  50  can position the arm structure  120  in a minimum height position  164 , which is disposed at a vertical distance  166  from a ground position  168 . At this minimum height position  164 , the adjustable height mechanism  56  vertically adapts the adjustable arm assembly  54  to the particular size and position of the target object  14 . For example, the adjustable arm assembly  54  may move the head structure  148  and mounted curing device  52  to the low mounting position  158 , as illustrated in FIG. 6. In the low mounting position  158 , the curing device  52  is positionable at or below the ground level  168 , such that the curing device  52  can cure the desired material at the base of the target object  14 . For example, the low mounting position  158  may be particularly advantageous for small-sized vehicles, pallet-mounted vehicles, or other target objects  14  positioned near the ground level  168 . As illustrated in FIG. 7, the adjustable arm assembly  54  also can move the head structure  148  and mounted curing device  52  to the high mounting position  156 . In the high mounting position  156 , the curing device  52  is positioned above the ground level  168  at a vertical height  170 , which relates to a vertical offset  172  provided between the high and low mounting positions  156  and  158 . Accordingly, the curing device  52  can cure the desired material at the base of a large-sized or high-positioned target object  14 , such as a large vehicle, a lift-mounted vehicle, and so forth.  
     [0027] As illustrated in FIGS. 8 and 9, the system  50  also can position the arm structure  120  in a maximum height position  174 , which disposes the arm structure  120  at a vertical distance  176  from the ground position  168 . At this maximum height position  174 , the adjustable height mechanism  56  vertically adapts the adjustable arm assembly  54  to the particular size and position of the target object  14 . The finish curing system  50  also may rotate the curing device  52  to a downwardly facing orientation, which facilitates curing of a desired material disposed on an upper surface of the target object  14 . If the target object  14  has a low topside, then the adjustable arm assembly  54  may move the head structure  148  and mounted curing device  52  to the low mounting position  158 , as illustrated in FIG. 8. In this low mounting position  158 , the heating/drying devices  144  and  146  are offset from the ground level  168  at a vertical distance  178 . As described above, the low mounting position  158  may be particularly advantageous for small-sized vehicles, pallet-mounted vehicles, or other low to the ground target objects  14 . The adjustable arm assembly  54  also can move the head structure  148  and mounted curing device  52  to the high mounting position  156 , as illustrated in FIG. 9. In the high mounting position  156 , the heating/drying devices  144  and  146  are disposed at a vertical height  180 , which is higher than the vertical height  178  by the vertical offset  172 . Accordingly, the curing device  52  can cure the desired material at the topside of a large-sized or high-positioned target object  14 , such as a large vehicle, a lift-mounted vehicle, and so forth.  
     [0028] While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.