Autonomous Robotic Coating Process Planning for Complex Geometries

TECHNOLOGY AREAS: Ground Sea; Air Platform; Space Platforms OBJECTIVE: This topic seeks to commercialize agile, autonomous robotic motion planning that achieves in-tolerance coating process results for arbitrarily sized, geometrically complex aerospace components (i.e., parts with concavities, holes, overhangs, etc.). DESCRIPTION: Agile task planning is a critical limiting factor for integrating robotics into low-volume, high-variability manufacturing and sustainment environments which are essential to the DAF's mission. For topology-driven tasks such as spray painting, agile task planning means defining a tool trajectory that accomplishes the manufacturing process objective over the surface of a workpiece, e.g., applying a specified coating thickness. Recent progress in agile, semi-autonomous robotic path planning has shown great promise, with some specific applications achieving pilot production, but only for smooth, convex surface topologies. A substantial gap exists for more complex geometries, which as of now, must be programmed by a human expert. Additionally, the current state-of-the-art is limited to path planning, focusing on the motion of the tool, when what is really needed is process planning, focusing on the result of the robotic process vis-a-vis the manufacturing process objective. For example, a toolpath that yields excellent results for electrostatic powder coating, where overspray is merely inconvenient, may yield terrible results if applied to painting, where overspray can ruin a coating. The ubiquity of topology-driven manufacturing processes in the DAF manufacturing and sustainment enterprise, and the fact that most aircraft and engine components have non-convex and discontinuous surfaces, creates a critical need to close these gaps. Failure to do so will continue to severely limit the application of robotic automation in the DAF manufacturing and sustainment enterprise. The objective is to develop collaborative robotic process planning systems that combine autonomous toolpath generation for complex geometries, manufacturing process simulation, and immersive user interaction in a manner that makes automation of batch-size-one operations practical. The vision is a system that automatically plans the process, presents the plan and simulation results to a human task expert, and provides an intuitive interface for the human to evaluate, modify, and ultimately approve the process plan. PHASE I: As this is a Direct-to-Phase-II (D2P2) topic, no Phase I awards will be made as a result of this topic. To qualify for this D2P2 topic, the Air Force expects the applicant(s) to demonstrate feasibility by means of a prior Phase I-type effort that does not constitute work undertaken as part of a prior or ongoing SBIR/STTR funding agreement. The feasibility study shall prove through prior research and development that the applicant has demonstrated robotic scan and plan spray coating that adapts robotic motion and tool path to as-built geometry that deviates from nominal geometry. Proof can be provided by direct demonstrations of any or all of the aforementioned capabilities, or through a combination of direct demonstrations and proposed modifications to an existing system to achieve the project goals. In the latter case, the applicant shall provide in-depth details on modifications necessary to achieve the desired capability. Modifications should utilize commercially available technologies. PHASE II: Under the Phase II effort, the awardee shall sufficiently develop the technology to the point where it can be physically demonstrated on aerospace relevant complex parts with aerospace relevant coating systems. The awardee(s) must identify technology hurdles they are expected to encounter during the development program, as well as potential solutions to mitigate risk to the program. PHASE III DUAL USE APPLICATIONS: The awardee(s) will implement the technology developed under the Phase II effort in hardware for a defense aerospace relevant robotic coating application and validate performance and achievement of objectives in pilot production at a USAF air logistics center. Key to this demonstration is to illustrate the system's adaptivity to new geometries and variation in known geometries without programming and with minimal human input and expertise. The contractor will pursue commercialization of the various technologies developed in Phase II for transitioning the technology to various defense aerospace OEMs, their supply chain, and the Air Force and broader DoD organic industrial base. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: 1. Brown, S. and Pierson, H.A. (2020) Adaptive Path Planning of Novel Complex Parts for Industrial Spraying Operations. Production and Manufacturing Research, 8(1), 335-368. 2. James, B and Pierson, H.A. (2019) Modeling and Simulation of Industrial Waterjet Stripping for Complex Geometries. International Journal of Advanced Manufacturing Technology, 105(5), 2431-2446. KEYWORDS: robotic coating; robotic painting; advanced robotics; adaptive robotics; robotic tool path planning