Patent Description:
Spray applicators apply a fluid coating to a component by propelling and directing the fluid with air. A percentage of the fluid coating will become airborne within the manufacturing environment. Sprayed fluid coating not applied to a component may result in overspray. Overspray produces additional material cost. Overspray may also settle on surrounding structures in the manufacturing environment. The fraction of sprayed fluid coating applied to a component may be described as a coverage percentage.

Applying a fluid coating inside tight areas of enclosures using spray end effectors may result in less than desirable coverage. For example, applying a fluid coating inside tight areas of enclosures may impact ability to access and spray adequately all surfaces using spray end effectors. Maneuvering spray end effectors may be undesirably difficult within tight areas of enclosures.

Manually applying a fluid coating inside tight areas of enclosures may take an undesirably large amount of time. Manually applying a fluid coating inside tight areas of enclosures may take an undesirably large number of human operators. Manually applying a fluid coating using human operators may cause an undesirable amount of exposure to the fluid coating or components of the fluid coating for the human operators.

For example, it would be desirable to reduce the amount of overspray in a coating system for tight areas of enclosures. Also, it would be desirable to reduce the amount of airborne fluid within a manufacturing environment when applying a coating to tight areas of enclosures. It would be desirable to provide an apparatus to increase the coverage of a coating within tight areas of enclosures.

<CIT>, in accordance with its abstract, states that a high volume, low pressure paint spray gun is provided with a spray gun body which is in fluid communication with a paint source, an atomization air source for atomizing paint and a shaping air source for shaping paint spray patterns. The spray gun is further provided with a nozzle which defines a paint atomizing zone for discharging atomized paint and a paint spray pattern shaping zone shaping atomized paint spray patterns. The spray gun is further provided with a paint hose, atomization air hose, and shaping air hose each having an inlet end which is connected to the spray gun body and a discharge end which is connected to the nozzle. The spray gun is further provided with a bendable, shape-retaining paint conduit having an inlet port which is connectable to the spray gun body and an outlet port which is connectable to the nozzle. The hoses extend through and are contained within the paint conduit. The paint conduit allows the nozzle to be self-supporting for maintaining the paint atomizing and shaping zones remote from and at any angle relative to the spray gun body for selectively discharging atomized paint and shaping resulting paint spray patterns thereof.

<CIT>, in accordance with its abstract, states that a spray head for paint spray with air and material nozzles and the control and/or supply device are linked for material and air supply by flexible hoses as enclosed in an extension tube. The nozzle control head for material etc application is joined to a spring loaded control piston and the air control line in the head issues into the piston space. Additional components include the nozzle head and spray air connection and material feed connection as well as control air connection and round spray air connection.

<CIT>, in accordance with its abstract, states that an atomiser pistol robot adapter has a number of pipes extending between a robot arm and an atomiser pistol, to connect channels in the robot arm and atomiser pistol. At least one pipe is for coating material and at least one other pipe is for pressurised air, to operate the atomiser pistol. The pipes are fixed to walls in the robot arm and atomiser pistol sides, and pass through openings in the walls.

Embodiments of the invention are claimed in independent claims. Some preferred embodiments are further claimed in the dependent claims.

An illustrative embodiment of the present disclosure provides a high-volume low-pressure end effector. The high-volume low-pressure end effector comprises a connection arm and a spray head. The connection arm comprises a housing with flexible conduits running through the housing. The spray head has integral channels configured to receive air and a fluid from the conduits and deliver the air and the fluid to a number of outlets.

Another illustrative embodiment of the present disclosure provides a method. A fluid and air are supplied through flexible conduits running through a housing of a connection arm to a spray head with integral channels configured to receive the air and the fluid from the conduits and deliver the air and the fluid to a number of outlets of the spray head, wherein the connection arm and spray head are components of a high-volume low-pressure end effector. The fluid is sprayed from at least one outlet of the number of outlets and onto surfaces of an enclosure of a structure with a total coverage of at least <NUM> percent.

A further illustrative embodiment of the present disclosure provides a high-volume low-pressure end effector. The high-volume low-pressure end effector comprises an attachment bracket, a connection arm, fittings, and a spray head. The attachment bracket covers valves for air and fluid. The connection arm comprises a hollow metal housing with flexible conduits running through the housing. The flexible conduits carry the air and the fluid. The fittings connect the flexible conduits to integral channels within a spray head. The spray head has integral channels delivering fluid and air to a number of outlets.

The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that spar cavities are large enclosures with tight areas for coating coverage.

The illustrative embodiments also recognize and take into account that conventional end effectors provide a low effective coverage of the spar cavities. The illustrative embodiments recognize and take into account that some conventional end effectors provide approximately <NUM> percent coverage within spar cavities.

The illustrative embodiments recognize and take into account that low coverage leads to low utilization of the robotic system. The illustrative embodiments recognize and take into account that the low coverage leads to increased flow time. The illustrative embodiments recognize and take into account that low coverage may result in a large amount of manual touch-up.

The illustrative embodiments recognize and take into account that many available spray paints, pigments, and other coatings contain hexavalent chromium. The illustrative embodiments recognize and take into account that minimizing human operator exposure to hexavalent chromium is desirable. The illustrative embodiments thus recognize and take into account that automating application of paints, pigments, and other coatings is desirable.

The illustrative embodiments recognize and take into account that some conventional end effectors are made from machined aluminum. The illustrative embodiments recognize and take into account that conventional end effectors with machined aluminum blocks are heavier than robotic arm operating payload standards. The illustrative examples recognize and take into account that because some conventional end effectors are mostly machined billet aluminum, components of these end effector may be undesirably difficult or expensive to find and replace.

With reference now to the figures, and in particular, with reference to <FIG>, an illustration of an aircraft is depicted in accordance with an illustrative embodiment. In this illustrative example, aircraft <NUM> has wing <NUM> and wing <NUM> attached to body <NUM>. Aircraft <NUM> includes engine <NUM> attached to wing <NUM> and engine <NUM> attached to wing <NUM>.

Body <NUM> has tail section <NUM>. Horizontal stabilizer <NUM>, horizontal stabilizer <NUM>, and vertical stabilizer <NUM> are attached to tail section <NUM> of body <NUM>.

Aircraft <NUM> is an example of an aircraft in which components coated using a high-volume low-pressure end effector may be implemented in accordance with an illustrative embodiment. For example, a high-volume low-pressure end effector may be used to apply coatings within wing spar cavities of at least one of wing <NUM> or wing <NUM>.

As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items may be used, and only one of each item in the list may be needed. In other words, "at least one of" means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, a thing, or a category.

For example, "at least one of item A, item B, or item C" may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In other examples, "at least one of" may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

This illustration of aircraft <NUM> is provided for the purposes of illustrating one environment in which different illustrative embodiments may be implemented. The illustration of aircraft <NUM> in <FIG> is not meant to imply architectural limitations as to the manner in which different illustrative embodiments may be implemented. For example, aircraft <NUM> is shown as a commercial passenger aircraft. The different illustrative embodiments may be applied to other types of aircraft, such as a private passenger aircraft, rotorcraft, or other suitable types of aircraft.

Although the illustrative examples for an illustrative embodiment are described with respect to an aircraft, the illustrative embodiments may be applied to other types of structures. The structure may be, for example, a mobile structure, a stationary structure, a land-based structure, an aquatic-based structure, or a space-based structure. More specifically, the structure may be a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, a manufacturing facility, a building, or other suitable types of structures.

Turning now to <FIG>, an illustration of a block diagram of a manufacturing environment is depicted in accordance with an illustrative embodiment. Manufacturing environment <NUM> is an illustrative example of an environment in which components of aircraft <NUM> may be processed. For example, fluid <NUM> may be applied to components of aircraft <NUM> using high-volume low-pressure end effector <NUM> in manufacturing environment <NUM>.

High-volume low-pressure end effector <NUM> comprises connection arm <NUM> and spray head <NUM>. Connection arm <NUM> comprises housing <NUM> with flexible <NUM> conduits <NUM> running through housing <NUM>. Spray head <NUM> has integral channels <NUM> configured to receive air <NUM> and fluid <NUM> from conduits <NUM> and deliver air <NUM> and fluid <NUM> to number of outlets <NUM>.

As used herein, a "number of items" means one or more items. For example, number of outlets <NUM> has one or more outlets.

In some illustrative examples, number of outlets <NUM> comprises first outlet <NUM> and second outlet <NUM> connected to integral channels <NUM>. First outlet <NUM> and second outlet <NUM> may have any desirable orientation relative to each other. First outlet <NUM> and second outlet <NUM> may be positioned anywhere from approximately zero degrees to approximately one hundred eighty degrees relative to each other. In some illustrative examples, first outlet <NUM> and second outlet <NUM> are pointed ninety degrees relative to each other. In other illustrative examples, first outlet <NUM> and second outlet <NUM> are pointed approximately one hundred eighty degrees relative to each other.

High-volume low-pressure end effector <NUM> comprises a respective nozzle and aircap for each of first outlet <NUM> and second outlet <NUM>. As depicted, nozzle <NUM> and aircap <NUM> are associated with first outlet <NUM>. Nozzle <NUM> and aircap <NUM> are associated with second outlet <NUM>. In some illustrative examples, high-volume low-pressure end effector <NUM> comprises a respective aircap threaded on to each of number of outlets <NUM>, wherein each respective aircap encloses a respective nozzle within each of number of outlets <NUM>.

Nozzle <NUM> and aircap <NUM> enable high-volume low-pressure application of fluid <NUM>. Nozzle <NUM> pressurizes fluid <NUM> and distributes the atomized fluid to aircap <NUM>. Aircap <NUM> allows pass-through of fluid <NUM> and distributes the atomized fluid to manufacturing environment <NUM>. Nozzle <NUM> and aircap <NUM> enable high-volume low-pressure spray of fluid <NUM> from first outlet <NUM>.

Nozzle <NUM> and aircap <NUM> enable high-volume low-pressure application of fluid <NUM>. Nozzle <NUM> pressurizes fluid <NUM> and distributes the pressurized fluid to aircap <NUM>. Aircap <NUM> allows pass-through of fluid <NUM> and distributes the atomized fluid to manufacturing environment <NUM>. Nozzle <NUM> and aircap <NUM> enable high-volume low-pressure spray of fluid <NUM> from second outlet <NUM>.

A combination of aircap <NUM> and spray head <NUM> holds and seals nozzle <NUM> within first outlet <NUM>. In some illustrative examples, aircap <NUM> is threaded onto spray head <NUM> to seal aircap <NUM> against spray head <NUM>. In this illustrative example, additional sealing components such as o-rings or other sealing components are not used to seal aircap <NUM> to spray head <NUM>. By not using additional sealing components, weight <NUM> of high-volume low-pressure end effector <NUM> may be reduced. By not using additional sealing components, maintenance time of high-volume low-pressure end effector <NUM> may be reduced.

A combination of aircap <NUM> and spray head <NUM> holds and seals nozzle <NUM> within second outlet <NUM>. In some illustrative examples, aircap <NUM> is threaded onto spray head <NUM> to seal aircap <NUM> against spray head <NUM>. In this illustrative example, additional sealing components such as o-rings or other sealing components are not used to seal aircap <NUM> to spray head <NUM>.

Integral channels <NUM> distribute air <NUM> and fluid <NUM> to the nozzles associated with spray head <NUM>. Integral channels <NUM> distribute air <NUM> and fluid <NUM> to nozzle <NUM> and nozzle <NUM>.

Spray head <NUM> is formed of any desirable material. Material <NUM> is selected to be compatible with use of fluid <NUM>. When fluid <NUM> is paint, material <NUM> is selected to be paint compatible. For example, material <NUM> is selected to not be reactive to fluid <NUM> or to solvents used to remove fluid <NUM> from spray head <NUM>. In one illustrative example, material <NUM> is stainless steel.

In accordance with independent claims <NUM> and <NUM>, spray head <NUM> is monolithic <NUM>. When spray head <NUM> is monolithic <NUM>, spray head <NUM> is one indivisible component.

Spray head <NUM> may be manufactured using any desirable method. In some illustrative examples, spray head <NUM> is formed using an additive manufacturing method. In some other illustrative examples, spray head <NUM> is formed by machining. In yet other illustrative examples, spray head <NUM> may be formed by molding or other manufacturing techniques. In some illustrative examples, a manufacturing technique for creating spray head <NUM> is selected based on at least one of a desirable manufacturing time, a desirable manufacturing cost, a desirable manufacturing accuracy, or any other manufacturing factors.

Integral channels <NUM> extend from first end <NUM> of spray head <NUM> towards second end <NUM> of spray head <NUM>. First end <NUM> is opposite second end <NUM> of spray head <NUM>. Integral channels <NUM> have any desirable shape and size to deliver air <NUM> and fluid <NUM> to number of outlets <NUM>. Fittings <NUM> connect conduits <NUM> in connection arm <NUM> to integral channels <NUM> of spray head <NUM>. Fittings <NUM> are associated with inlets <NUM> of integral channels <NUM> at first end <NUM> of spray head <NUM>. Fittings <NUM> are physically connected to integral channels <NUM> using any desirable type of connection. In some illustrative examples, fittings <NUM> are threaded. In these illustrative examples, torque is applied to secure fittings <NUM> to spray head <NUM>.

In high-volume low-pressure end effector <NUM>, fittings <NUM> comprise number of air fittings <NUM> and number of fluid fittings <NUM>. In some illustrative examples, number of air fittings <NUM> comprises two air fittings per outlet, and wherein number of fluid fittings <NUM> comprises one fluid fitting per outlet. In these illustrative examples, a first air fitting supplies air <NUM> to atomize fluid <NUM> exiting the respective nozzle. In these illustrative examples, a second air fitting supplies air <NUM> to form shaping air streams. The second air fitting provides shaping air streams to control application of fluid <NUM> and evenly distribute fluid <NUM>.

The quantity of conduits <NUM> is any desirable quantity. In some illustrative examples, the quantity of conduits <NUM> is equal to the quantity of fittings <NUM>.

In some illustrative examples, the quantity of conduits <NUM> is affected by the quantity of outlets in number of outlets <NUM>. For example, each outlet of number of outlets <NUM> will receive air <NUM> and fluid <NUM>. The quantity of conduits <NUM> will be sufficient to provide air <NUM> and fluid <NUM> to each outlet of number of outlets <NUM>.

When number of outlets <NUM> is one outlet, conduits <NUM> contains at least one conduit with fluid <NUM> and at least two conduits with air <NUM>. When number of outlets <NUM> is two outlets, conduits <NUM> contains at least two conduits with fluid <NUM> and at least four conduits with air <NUM>.

Spray head <NUM> is replaceable. In some illustrative examples, spray head <NUM> may be replaced with a spray head with a different quantity of outlets. In these illustrative examples, conduits <NUM> may remain in housing <NUM> after spray head <NUM> is replaced. In these illustrative examples, conduits <NUM> may contain a larger quantity of conduits than a quantity of outlets or a quantity of nozzles in the replacement spray head.

First end <NUM> of spray head <NUM> is connected to connection arm <NUM>. Spray head <NUM> is connected to connection arm <NUM> using fasteners <NUM>. In some illustrative examples, the connection between connection arm <NUM> and spray head <NUM> has a minimal quantity of fasteners <NUM>. A minimal quantity of fasteners <NUM> may reduce weight <NUM> of high-volume low-pressure end effector <NUM>. A minimal quantity of fasteners <NUM> may also reduce maintenance time for high-volume low-pressure end effector <NUM>. Fasteners <NUM> are selected to not extend from connection arm <NUM> an undesirable amount.

In some illustrative examples, first end <NUM> is inserted into housing <NUM> prior to connecting spray head <NUM> and connection arm <NUM>. In some illustrative examples, spray head <NUM> reduces in cross-sectional area moving from first end <NUM> to second end <NUM>. By reducing in cross-sectional area, spray head <NUM> may maneuver within tight areas more easily.

Connection arm <NUM> has housing <NUM>. Housing <NUM> has cross-section <NUM>. Cross-section <NUM> is selected to accommodate conduits <NUM>. In some illustrative examples, cross-section <NUM> is selected to reduce chances of collision of housing <NUM> during rotation.

In some illustrative examples, cross-section <NUM> is circular <NUM>. In these illustrative examples, housing <NUM> has circular <NUM> cross-section <NUM>. When cross-section <NUM> is circular <NUM>, deflection is lower than for cross-sections with sharp corners.

In some illustrative examples, housing <NUM> is hollow <NUM> to accommodate conduits <NUM>. In some illustrative examples, housing <NUM> is hollow <NUM> to reduce weight <NUM> of high-volume low-pressure end effector <NUM>.

Connection arm <NUM> is formed of material <NUM>. Connection arm <NUM> may be formed of any desirable material. In some illustrative examples, material <NUM> of housing <NUM> is selected based on at least one of strength, rigidity, or weight. In some illustrative examples, material <NUM> of housing <NUM> is metal <NUM>. In some illustrative examples, housing <NUM> is hollow <NUM> metal <NUM> housing <NUM>. In one illustrative example, housing <NUM> may be formed of aluminum.

Attachment bracket <NUM> attaches connection arm <NUM> to connector <NUM>. Attachment bracket <NUM> is designed to reduce weight <NUM> of high-volume low-pressure end effector <NUM>. Attachment bracket <NUM> may take the form of a number of hollow components fastened together.

Valves <NUM> control the flow of fluid <NUM> and air <NUM> through high-volume low-pressure end effector <NUM>. In this illustrative example, valves <NUM> are positioned within attachment bracket <NUM>. By positioning valves <NUM> near robotic arm <NUM>, movement of robotic arm <NUM> is easier. Positioning valves <NUM> within attachment bracket <NUM> creates a reduced moment of inertia for robotic arm <NUM> and high-volume low-pressure end effector <NUM>.

Connector <NUM> connects high-volume low-pressure end effector <NUM> to robotic arm <NUM>. When connector <NUM> is quick-change tool <NUM>, high-volume low-pressure end effector <NUM> may be quickly removed from robotic arm <NUM>. Conduits <NUM> within connector <NUM> pass fluid <NUM> and air <NUM> through connector <NUM>.

Robotic arm <NUM> maneuvers high-volume low-pressure end effector <NUM> within manufacturing environment <NUM>. Robotic arm <NUM> is used to maneuver high-volume low-pressure end effector <NUM> to spray fluid <NUM> onto portions of structure <NUM>.

Structure <NUM> has enclosure <NUM>. Robotic arm <NUM> maneuvers high-volume low-pressure end effector <NUM> within enclosure <NUM> to apply fluid <NUM> to enclosure <NUM> with coverage <NUM>. Coverage <NUM> is within a desirable range. In some illustrative examples, coverage <NUM> is desirably above <NUM> percent. In some illustrative examples, coverage <NUM> is desirably above <NUM> percent. In some illustrative examples, coverage <NUM> may be about <NUM> percent.

In one illustrative example, high-volume low-pressure end effector <NUM> comprises attachment bracket <NUM> containing valves <NUM> for air <NUM> and fluid <NUM>; connection arm <NUM> comprising hollow <NUM> metal <NUM> housing <NUM> with flexible <NUM> conduits <NUM> running through housing <NUM>; flexible <NUM> conduits <NUM> carrying air <NUM> and fluid <NUM>; fittings <NUM> connecting flexible <NUM> conduits <NUM> to integral channels <NUM> within spray head <NUM>; and spray head <NUM> having integral channels <NUM> delivering fluid <NUM> and air <NUM> to number of outlets <NUM>.

The illustration of manufacturing environment <NUM> in <FIG> is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to, or in place of, the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.

Number of outlets <NUM> of spray head <NUM> has any desirable quantity of outlets. In some illustrative examples, number of outlets <NUM> may have only one outlet. In other illustrative examples, number of outlets <NUM> may have more than two outlets.

Turning now to <FIG>, an illustration of a manufacturing environment is depicted in accordance with an illustrative embodiment. Manufacturing environment <NUM> is a physical implementation of manufacturing environment <NUM> of <FIG>. Wing <NUM> in manufacturing environment <NUM> may be one of wing <NUM> or wing <NUM> of aircraft <NUM> in <FIG>.

As depicted, high-volume low-pressure end effector <NUM> is connected to robotic arm <NUM>. High-volume low-pressure end effector <NUM> is a physical implementation of high-volume low-pressure end effector <NUM> of <FIG>. High-volume low-pressure end effector <NUM> is positioned within wing spar cavity <NUM> of wing <NUM>. During operation, high-volume low-pressure end effector <NUM> will be maneuvered by robotic arm <NUM> to apply a coating, such as paint or other desirable coating, to wing spar cavity <NUM>.

Turning now to <FIG>, an illustration of an isometric view of a high-volume low-pressure end effector is depicted in accordance with an illustrative embodiment. High-volume low-pressure end effector <NUM> is a physical implementation of high-volume low-pressure end effector <NUM> of <FIG>. High-volume low-pressure end effector <NUM> may be used to apply a coating to a component of aircraft <NUM> of <FIG>. High-volume low-pressure end effector <NUM> may be a physical implementation of high-volume low-pressure end effector <NUM> of <FIG>.

High-volume low-pressure end effector <NUM> comprises connector <NUM>, attachment bracket <NUM>, connection arm <NUM>, and spray head <NUM>. Connector <NUM> is used to connect high-volume low-pressure end effector <NUM> to a robotic arm, such as robotic arm <NUM> of <FIG>. In some illustrative examples, connector <NUM> is a quick-change connector.

Attachment bracket <NUM> attaches connection arm <NUM> to connector <NUM>. In some illustrative examples, attachment bracket <NUM> encompasses valves to control spray of fluid from high-volume low-pressure end effector <NUM>.

Connection arm <NUM> lengthens high-volume low-pressure end effector <NUM>. Connection arm <NUM> has a desirable length to position spray head <NUM> within tight areas of enclosures. A cross-section of connection arm <NUM> is configured to maneuver spray head <NUM> within tight areas of enclosures.

Turning now to <FIG>, an illustration of an exploded view of a high-volume low-pressure end effector is depicted in accordance with an illustrative embodiment. View <NUM> is an exploded view of high-volume low-pressure end effector <NUM> of <FIG>. In view <NUM>, valves <NUM> are visible.

In view <NUM>, pins <NUM> connecting connection arm <NUM> to attachment bracket <NUM> are visible. Pins <NUM> are configured to provide a desired alignment of spray head <NUM> within high-volume low-pressure end effector <NUM>.

Pins <NUM> may have any desirable quantity of pins. In some illustrative examples, pins <NUM> have a minimal quantity of pins.

In view <NUM>, pins <NUM> connecting spray head <NUM> to connection arm <NUM> are visible. Pins <NUM> are configured to provide a desired alignment of spray head <NUM> within high-volume low-pressure end effector <NUM>. Pins <NUM> may have any desirable quantity of pins. In some illustrative examples, pins <NUM> have a minimal quantity of pins.

In view <NUM>, number of outlets <NUM> of spray head <NUM> is visible. In this illustrative example, number of outlets <NUM> includes first outlet <NUM> and second outlet <NUM>.

As depicted, high-volume low-pressure end effector <NUM> also has a respective nozzle and a respective aircap for each of first outlet <NUM> and second outlet <NUM>. Nozzle <NUM> and aircap <NUM> are associated with first outlet <NUM>. Nozzle <NUM> and aircap <NUM> are associated with second outlet <NUM>.

Turning now to <FIG>, an illustration of a cross-sectional view of a high-volume low-pressure end effector is depicted in accordance with an illustrative embodiment. View <NUM> is a cross-sectional view of high-volume low-pressure end effector <NUM> of <FIG>.

In view <NUM>, valves <NUM> controlling the flow of fluid and air through high-volume low-pressure end effector <NUM> are visible within attachment bracket <NUM>. Valves <NUM> control the flow of fluid and air through flexible conduits <NUM> running through housing <NUM> of connection arm <NUM>. Spray head <NUM> has integral channels <NUM> configured to receive air and fluid from flexible conduits <NUM> and deliver the air and fluid to number of outlets <NUM>.

Turning now to <FIG>, an illustration of an isometric view of a connection arm is depicted in accordance with an illustrative embodiment. View <NUM> is an isometric view of connection arm <NUM> of <FIG>.

Connection arm <NUM> comprises housing <NUM> with flexible conduits <NUM> running through housing <NUM>. As depicted, housing <NUM> is hollow. In some illustrative examples, housing <NUM> is a hollow metal housing.

Flexible conduits <NUM> will be connected to fittings <NUM> of spray head <NUM> depicted in <FIG>. In this illustrative example, the quantity of flexible conduits <NUM> is the same as quantity of fittings <NUM>. In some illustrative examples, when a spray head other than spray head <NUM> is used, the quantity of flexible conduits <NUM> may be greater than fittings of a spray head.

As depicted, flexible conduits <NUM> comprises six conduits. Flexible conduits <NUM> includes three conduits for each outlet of spray head <NUM>. Flexible conduits <NUM> comprises one fluid conduit and two air conduits for each outlet of spray head <NUM>.

In other illustrative examples, spray head <NUM> may include a different quantity of outlets. For example, spray head <NUM> may have more than two outlets. In some illustrative examples, when spray head <NUM> has more than two outlets, the quantity of flexible conduits <NUM> will be greater than six. In one illustrative example, when spray head <NUM> has three outlets, the quantity of flexible conduits <NUM> will be nine flexible conduits. When spray head <NUM> has less than two outlets, the quantity of flexible conduits <NUM> may be less than six. In some illustrative examples, spray head <NUM> may only have one outlet. In this illustrative example, quantity of flexible conduits <NUM> may be three.

Turning now to <FIG>, an illustration of a front view of a connection arm is depicted in accordance with an illustrative embodiment. View <NUM> is a view from direction <NUM> of <FIG>. View <NUM> is a front view of connection arm <NUM> of <FIG>.

View <NUM> is a view of end <NUM> of connection arm <NUM> that will connect to spray head <NUM>. In view <NUM>, ends <NUM> of flexible conduits <NUM> are visible. Ends <NUM> will be connected to fittings (not depicted) of spray head <NUM> of <FIG>.

Turning now to <FIG>, an illustration of a back view of a connection arm is depicted in accordance with an illustrative embodiment. View <NUM> is a view from direction <NUM> of <FIG>. View <NUM> is a back view of connection arm <NUM> of <FIG>. View <NUM> is a view of end <NUM> of connection arm <NUM> that will connect to attachment bracket <NUM>.

Turning now to <FIG>an illustration of a cross-sectional view of a connection arm is depicted in accordance with an illustrative embodiment. View <NUM> is a cross-sectional view of connection arm <NUM> of <FIG>.

Turning now to <FIG>, an illustration of a cross-sectional view of a connection arm connected to a spray head is depicted in accordance with an illustrative embodiment. View <NUM> is a cross-sectional view of connection arm <NUM> connected to spray head <NUM> of <FIG>.

In view <NUM>, ends <NUM> of flexible conduits <NUM> are connected to fittings <NUM> of spray head <NUM>. Fittings <NUM> form connections between flexible conduits <NUM> and integral channels <NUM>.

Turning now to <FIG>, an illustration of an isometric view of a spray head with nozzles and aircaps is depicted in accordance with an illustrative embodiment. View <NUM> is an isometric view of spray head <NUM> separate from the remainder of high-volume low-pressure end effector <NUM>.

In view <NUM>, aircap <NUM> is secured to first outlet <NUM> of spray head <NUM>. Aircap <NUM> seals nozzle <NUM> of <FIG> within first outlet <NUM>. Aircap <NUM> is secured to second outlet <NUM> of spray head <NUM>. Aircap <NUM> seals nozzle <NUM> of <FIG> within second outlet <NUM>.

Turning now to <FIG>, an illustration of an exploded view of a spray head with nozzles and aircaps is depicted in accordance with an illustrative embodiment. View <NUM> is an exploded view of spray head <NUM> and associated nozzles and aircaps.

View <NUM> is a closer exploded view of spray head <NUM>, aircaps, and nozzles of <FIG>. In view <NUM>, threads <NUM> of first outlet <NUM> are visible. To secure nozzle <NUM> within first outlet <NUM>, aircap <NUM> is secured to first outlet <NUM> using threads <NUM>. In view <NUM>, threads <NUM> of second outlet <NUM> are visible. To secure nozzle <NUM> within second outlet <NUM>, aircap <NUM> is secured to second outlet <NUM> using threads <NUM>.

Turning now to <FIG>, an illustration of a back isometric view of a spray head with fittings is depicted in accordance with an illustrative embodiment. View <NUM> is a back isometric view of spray head <NUM> and associated nozzles, fittings, and aircaps.

As depicted, fittings <NUM> comprise air fittings <NUM> and fluid fittings <NUM>. Fluid fittings <NUM> include fluid fitting <NUM> providing fluid to first outlet <NUM> and fluid fitting <NUM> providing fluid to second outlet <NUM>. Air fittings <NUM> include air fittings <NUM> providing air to first outlet <NUM> and air fittings <NUM> providing air to second outlet <NUM>.

Fittings <NUM> will be connected to flexible conduits <NUM>. As depicted, the quantity of fittings <NUM> is the same as the quantity of flexible conduits <NUM>. Each of flexible conduits <NUM> will connect to a respective fitting of fittings <NUM>.

As depicted, fittings <NUM> comprises six fittings. Fittings <NUM> includes three fittings for each outlet, one fluid fitting and two air fittings. Air fittings <NUM> includes two air fittings. Air fittings <NUM> includes two air fittings.

In other illustrative examples, spray head <NUM> may include a different quantity of fittings. For example, spray head <NUM> may have more than two outlets. In some illustrative examples, when spray head <NUM> has more than two outlets, the quantity of fittings will be greater than six. In one illustrative example, when spray head <NUM> has three outlets, the quantity of fittings will be nine fittings. When spray head <NUM> has less than two outlets, the quantity of fittings will be less than six. For example, in some illustrative examples, spray head <NUM> may only have three fittings.

Turning now to <FIG>, an illustration of an isometric view of a spray head is depicted in accordance with an illustrative embodiment. View <NUM> is an isometric view of spray head <NUM>.

In view <NUM>, first outlet <NUM> and second outlet <NUM> are visible. As can be seen in view <NUM>, first outlet <NUM> and second outlet <NUM> are directed at ninety degrees relative to each other.

Turning now to <FIG>, an illustration of a cross-sectional view of a spray head is depicted in accordance with an illustrative embodiment. View <NUM> is a cross-sectional view of spray head <NUM>.

Turning now to <FIG>, an illustration of a partially transparent view of a spray head is depicted in accordance with an illustrative embodiment. View <NUM> is a transparent view of spray head <NUM> of <FIG>.

In view <NUM>, the material of spray head <NUM> is transparent while the boundaries of integral channels <NUM> are solid.

Spray head <NUM> is shown as only one non-limiting example of a physical implementation of spray head <NUM> of <FIG>. Spray head <NUM> may have any desirable number of outlets. In some illustrative examples, spray head <NUM> may have only one outlet. In other illustrative examples, spray head <NUM> may have more than two outlets.

Further, integral channels <NUM> may have any desirable shape or path within spray head <NUM>. Integral channels <NUM> are only one non-limiting example of integral channels that may be present within spray head <NUM>. Integral channels <NUM> are only one non-limiting example of integral channels <NUM> of <FIG>.

The different components shown in <FIG> and <FIG>-<NUM> may be combined with components in <FIG>, used with components in <FIG>, or a combination of the two. Additionally, some of the components in <FIG> and <FIG>-<NUM> may be illustrative examples of how components shown in block form in <FIG> may be implemented as physical structures.

Turning now to <FIG>, an illustration of a flowchart of a method for applying a fluid to surfaces of an enclosure of a structure is depicted in accordance with an illustrative embodiment. Method <NUM> may apply a fluid to at least one component of aircraft <NUM> of <FIG>. Method <NUM> may take place in manufacturing environment <NUM> of <FIG> using high-volume low-pressure end effector <NUM>. Method <NUM> may take place in manufacturing environment <NUM> of <FIG>. Method <NUM> may be performed using high-volume low-pressure end effector <NUM> of <FIG>.

Method <NUM> supplies a fluid and air through flexible conduits running through a housing of a connection arm to a spray head with integral channels configured to receive the air and the fluid from the conduits and deliver the air and the fluid to a number of outlets of the spray head, wherein the connection arm and spray head are components of a high-volume low-pressure end effector (operation <NUM>). Method <NUM> sprays the fluid from at least one outlet of the number of outlets and onto surfaces of an enclosure of a structure (operation <NUM>). Afterwards, the method terminates.

Method <NUM> connects a high-volume low-pressure end effector to a robotic arm using a quick-change tool (<NUM>). Method <NUM> supplies a fluid and air through flexible conduits running through a housing of a connection arm to a spray head with integral channels configured to receive the air and the fluid from the conduits and deliver the air and the fluid to a number of outlets of the spray head, wherein the connection arm and spray head are components of the high-volume low-pressure end effector (operation <NUM>). Method <NUM> controls a flow of the fluid and the air using valves within an attachment bracket of the high-volume low-pressure end effector, wherein the attachment bracket is connected to the connection arm (operation <NUM>). Method <NUM> sprays the fluid from at least one outlet of the number of outlets and onto surfaces of an enclosure of a structure (operation <NUM>). In some illustrative examples, the fluid is sprayed from the at least one outlet of the number of outlets and onto the surfaces of the enclosure of the structure with a coverage of at least <NUM> percent (operation <NUM>).

Method <NUM> performs maintenance on the high-volume low-pressure end effector by removing the flexible conduits from the connection arm and placing replacement flexible conduits within the connection arm (operation <NUM>). In some illustrative examples, performing maintenance further comprises attaching the conduits to fittings of the spray head (operation <NUM>).

Method <NUM> performs maintenance on the high-volume low-pressure end effector by disconnecting the flexible conduits from fittings of the spray head, removing the spray head, and connecting a replacement spray head to the connection arm (operation <NUM>). Afterwards, the method terminates.

The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatus and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams may represent a module, a segment, a function, and/or a portion of an operation or step.

In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added, in addition to the illustrated blocks, in a flowchart or block diagram.

Illustrative embodiments of the present disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. Turning first to <FIG>, an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> in <FIG> and material procurement <NUM>.

During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> takes place. Thereafter, aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

With reference now to <FIG>, an illustration of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> of <FIG> and may include airframe <NUM> with plurality of systems <NUM> and interior <NUM>. Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method <NUM>.

One or more illustrative embodiments may be used during at least one of component and subassembly manufacturing <NUM>, system integration <NUM>, or maintenance and service <NUM> of <FIG>. For example, high-volume low-pressure end effector <NUM> of <FIG> may be used during component and subassembly manufacturing <NUM> to spray a coating onto portions of airframe <NUM> of <FIG>. High-volume low-pressure end effector <NUM> of <FIG> may be used during component and subassembly manufacturing <NUM> according to method <NUM> of <FIG> or method <NUM> of <FIG>.

Fluid <NUM> may be sprayed onto components of aircraft <NUM> using high-volume low-pressure end effector <NUM> of <FIG> during system integration <NUM>. High-volume low-pressure end effector <NUM> may be used to spray a coating such as fluid <NUM> of <FIG> on replacement components used during maintenance and service <NUM> of <FIG>. Structure <NUM> may be at least a component of airframe <NUM>.

In some large enclosures, a long reach is required for high coverage. The illustrative examples provide an end of arm tooling with the ability to reach into the tight areas of a spar cavity and able to spray with both a zero degree spray tip as well as a ninety degree spray tip. The illustrative examples provide a system that is high-volume low-pressure (HVLP) compliant. The illustrative examples are safer for the manufacturing environment and operators than non-HVLP conventional end effectors.

The illustrative examples provide a high-volume low-pressure end effector with significantly increased coverage over conventional end effectors. The coverage of the high-volume low-pressure end effector of the illustrative examples is increased due to an increased length of the connection arm of the high-volume low-pressure end effector compared to conventional end effectors. The coverage of the high-volume low-pressure end effector of the illustrative examples is also increased due to the high-volume low-pressure capacity of the illustrative examples.

When coverage is increased, utilization of the robotic system having high-volume low-pressure end effector may also be higher than utilization of conventional end effectors. By increasing utilization of automation, the time to apply a coating to a structure is reduced. For example, increasing utilization of automation reduces the time to paint a wing. Increasing automation reduces manual application of coatings. Reducing manual application of coatings removes operators from an environment with airborne coatings. Reducing manual application of coatings reduces operator exposure to airborne coatings.

The illustrative examples present a high-volume low-pressure end effector with a lower weight than conventional end effectors. Several of the components of the high-volume low-pressure end effector are hollow to reduce the weight of the end effector compared to conventional end effectors.

The illustrative examples present a high-volume low-pressure end effector with better maintainability than conventional end effectors. Maintenance time is reduced by having fewer components. For example, high-volume low-pressure end effector does not have o-rings.

Further, at least one of maintenance time or maintenance cost may be reduced by having easily replicable and replaceable components. The use of flexible conduits allows for replacement of the conduits without replacing the whole of the connection arm. Not replacing the housing may result in less material waste and lower maintenance cost. By only replacing the flexible conduits during maintenance, the cost of maintenance may be reduced. For example, the flexible conduits may be formed of inexpensive material. As another example, the flexible conduits may be commercially available. By providing flexible conduits, different designs of the spray head may be interchangeable within the high-volume low-pressure end effector.

Claim 1:
A high volume low pressure spray end effector (<NUM>, <NUM>, <NUM>) for a robotic arm (<NUM>, <NUM>), the high volume low pressure spray end effector (<NUM>, <NUM>, <NUM>) comprising:
a connection arm (<NUM>, <NUM>) comprising a housing (<NUM>, <NUM>) with flexible (<NUM>) conduits (<NUM>, <NUM>) running through the housing (<NUM>, <NUM>), wherein a cross-section of the connection arm (<NUM>, <NUM>) is configured to maneuver a monolithic spray head (<NUM>, <NUM>) within tight areas of enclosures;
the spray head (<NUM>, <NUM>) with integral channels (<NUM>, <NUM>) configured to receive air (<NUM>) and a fluid (<NUM>) from the flexible (<NUM>) conduits (<NUM>, <NUM>) and deliver the air (<NUM>) and the fluid (<NUM>) to a number of outlets (<NUM>, <NUM>),
wherein the number of outlets (<NUM>, <NUM>) comprises a first outlet (<NUM>, <NUM>) and a second outlet (<NUM>, <NUM>) connected to the integral channels (<NUM>, <NUM>),
the high volume low pressure spray end effector (<NUM>, <NUM>, <NUM>) further comprises a respective nozzle (<NUM>, <NUM>, <NUM>, <NUM>) and aircap (<NUM>, <NUM>, <NUM>, <NUM>) for each of the first outlet (<NUM>, <NUM>) and the second outlet (<NUM>, <NUM>), and
a quantity of the flexible conduits (<NUM>, <NUM>) is at least six, including two of the flexible conduits (<NUM>, <NUM>) configured to provide air (<NUM>) to the first outlet (<NUM>, <NUM>), one of the flexible conduits (<NUM>) configured to provide fluid (<NUM>) to the first outlet (<NUM>, <NUM>), two of the flexible conduits (<NUM>) configured to provide air (<NUM>) to the second outlet (<NUM>, <NUM>), and one of the flexible conduits (<NUM>, <NUM>) configured to provide fluid (<NUM>) to the second outlet (<NUM>, <NUM>) .