FORM-2
THE PATENT ACT,1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
(As Amended)
COMPLETE SPECIFICATION
(See section 10;rule 13)
"AUTOMATIC SURFACE MODIFYING ROBOT"
Tata Projects Ltd, a corporation organized and existing under the laws of India, of One Boulevard Street, 2nd 3rd &
4th Floor, Lake Boulevard Rd, Powai, Mumbai 400076, India.
The following specification particularly describes the invention and the manner in which it is to be performed:
2
AUTOMATIC SURFACE MODIFYING ROBOT
FIELD OF INVENTION
Embodiments of the present application relates to automated painting methods, and more
5 specifically, a robot that is programmed to perform painting and polishing of different
surfaces.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present
10 invention. It is not an admission that any of the information provided herein is prior art or
relevant to the presently disclosed invention, or that any publication specifically or implicitly
referenced is prior art.
Currently, painting is generally done using direct human intervention where handheld spray
15 painting is a widely used technique. To overcome the large amount of time to finish the
operation, several automated painting techniques are used where the pain brush may be
defined to move along a certain predefined track or pathway so that a wall or floor is
uniformly painted. However, both direct painting by workers or track based automated
painting methods involve a large amount of cost and time. Furthermore, the finishing quality
20 of the painting work is also not guaranteed when performed using the above-mentioned
techniques.
Therefore, there is a need for device that can work faster and more efficiently than a human
could ever be able to. There is a need for an end effector management device, considering a
25 painting and polishing device as an example, which works at least 10 times faster and more
productive than the conventional methods. Such kind of an end effector management device
should facilitate benefits that include cost savings, minimal material wastage, increased
productivity, consistent quality, reliance on labour is reduced by 80%, and much more. Such
automation of on-site construction job will prevent the exposure of human workers to
30 potential risks, such as working in heights and working with toxic materials.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the subject matter to provide a basic
understanding of some of the aspects of subject matter embodiments. This summary is not an
3
extensive overview of the subject matter. It is not intended to identify key/critical elements of
the embodiments or to delineate the scope of the subject matter. Its sole purpose to present
some concepts of the subject matter in a simplified form as a prelude to the more detailed
description that is presented later.
5
An automatic surface modifying robot (50) disclosed here addresses the above-mentioned
need for an end effector management device, which works at least 10 times faster and more
productive than the conventional methods. Such kind of an end effector management device
should facilitate benefits that include cost savings, minimal material wastage, increased
10 productivity, consistent quality, reliance on labour is reduced by 80%, and much more. The
automatic surface modifying robot (50) comprises a linear actuation unit (1), a rotary
actuation unit (2), an end effector (5), and an omni wheel assembly (15. The linear actuation
unit (1) is mounted on a vertical frame for vertical reciprocating movement and motion
control of an end effector (5), where the end effector (5) is programmed to move in a
15 predefined line with a consistent speed. The rotary actuation unit (2) is mechanically engaged
with the linear actuation unit (1), where the rotary actuation unit (2) moves the end effector
(5) along different angles. Here, the end effector (5) that is for example, a spray gun (5a)
[FIGURE 1C] or a polishing tool (5b) [FIGURE 13A], is equipped with a programmed
algorithm for consistent speed during movement, where the end effector (5) is electrically
20 synchronized with the rotary actuation unit (2) and the linear actuation unit (1) to control
movement of the end effector (5) along the different angles. The omni wheel assembly (15) is
positioned below a machine cabinet (4) of the automatic surface modifying robot (50), where
the omni wheel assembly (15) comprises round wheels that are placed in a circular formation,
so that the round wheels are turnable in different directions, which allows the automatic
25 surface modifying robot (50) to move in all directions.
In an embodiment, the vertical frame is an aluminium profile base frame. In an embodiment,
the linear actuation unit (1) comprises a first actuator (1a) and a second actuator (1b) that are
independent of each other, where the first actuator (1a) and the second actuator (1b) functions
30 in tandem to provide precise linear synchronization therebetween to generate a specific
motion profile of the end effector (5). In an embodiment, the rotary actuation unit (2)
comprises: a bearing housing (2.1) that is made of aluminium, a bearing (2.2) that is
positioned within the bearing housing (2.1), a servo motor (2.3) positioned in the bearing
housing (2.1) to provide incremental movement of the rotary actuation unit (2), a gearbox
4
(2.4) with a gear ratio 10:1 for working of the motor, a solenoid coil (2.5) for triggering of the
end effector (5), and a bevel gear (2.6) with a pressure angle of 20 degrees, comprising a
perpendicular contact axis.
5 In an embodiment, the automatic surface modifying robot (50) further comprises a human
machine interface HMI (14), which is a graphical user interface that allows an operator to
connect and control the linear actuation unit (1) and the rotary actuation unit (2), where the
operator is enabled to diagnose technical condition of the automatic surface modifying robot
(50).
10
In an embodiment, the automatic surface modifying robot (50) further comprises a PLC (98)
that is positioned in communication with the HMI (14), which receives input signals from
sensors (94a, 94b, 94c, and 95) and then processes the signals to produce output signals to a
control motor (81) and servo motors (82a and 82b) that drive the linear actuation unit (1) and
15 the rotary actuation unit (2) and drive wheels (15a).
In an embodiment, the machine cabinet (4) as shown in FIGURE 5, is positioned at a lower
section along the vertical frame, where the machine cabinet (4) is made of fibre reinforced
polymer (FRP) composite material. In an embodiment, the omni wheel assembly (15)
20 comprises shock absorbers (66) that are mounted on a connection bar (76) that is connected
to the omni wheel assembly (15), where the shock absorbers (66) enable seamless traversal of
the automatic surface modifying robot (50) on uneven surfaces. In an embodiment, the end
effector (5) is, for example, a spray gun (5a) or a polishing tool (5b). In an embodiment, the
automatic surface modifying robot (50) further comprises an airless paint pump (3) that is
25 connected to the spray gun (5a), where the airless paint pump (3) delivers a consistent level
of pressure, regardless of type of paint material that is sprayed, and provides a consistent
paint job without any drips and runs, and where the design of the airless paint pump (3)
allows users to spray paint without need of air pressure.
30 In an embodiment, the automatic surface modifying robot (50) further comprises an
autonomous mobile robot (AMR) (11) as shown in FIGURES 1A and 2F, which is designed
to make the automatic surface modifying robot (50) more portable and rotatable in all
directions. The AMR (11) prevents the automatic surface modifying robot (50) from
obstacles along different paths that the automatic surface modifying robot (50) is
5
programmed to follow to reach predefined locations, and where the AMR (11) follows a
virtual programmable path on floor as per a floor plan as shown in FIGURE 10C. In an
embodiment, the automatic surface modifying robot (50) further comprises a gearbox (6) that
comprises planetary gear assembly (83) that are used to drive wheels (15a) and the linear
5 actuation unit (1). The planetary gear assembly (83) is composed of multiple planetary gears
(84) that rotate around a central sun gear (85), which is connected to an output shaft (86a),
where torque generated is transferred from an input shaft (86b) to the output shaft (86a),
providing increased torque and decreased backlash.
10 In an embodiment, the automatic surface modifying robot (50) further comprises a teach
pendant (7), which is positioned at a front section of the automatic surface modifying robot
(50), which is controllable wirelessly via a Wi-Fi enabled mobile tab, where the teach
pendant (7) allows a user to control the automatic surface modifying robot (50) from a
distance. In an embodiment, the automatic surface modifying robot (50) further comprises a
15 solenoid actuator (87), which is electromagnetic solenoid actuator (87) that is used to open
and close a solenoid valve (88) of the end effector (5), to precise and repeatable movement of
the end effector (5), which is a spray gun (5a). In an embodiment, the servo motors (82a and
82b) provide absolute positioning of the automatic surface modifying robot (50), where the
servo motors (82a and 82b) use feedback from a position encoder to precisely control the
20 position, which allows servo motors (82a and 82b) to move to a specific position, even when
the control motor (81) is started and stopped multiple times.
In an embodiment, in claim 1, where the linear actuation unit (1) comprises a ball screw and
nut assembly (89), a linear guide (90), a block (91), a bearing support (92), and an aluminium
25 extrusion profile (93). The ball screw and nut assembly (89) translates rotational motion to
linear motion of the linear actuation unit (1) with reduced friction, where the ball screw and
nut assembly (89) comprises a threaded shaft (89a) that provides a helical raceway for ball
bearings, which is positioned in form of a precision screw. The linear guide (90) of the linear
actuation unit (1) includes bearings for rotary motion to move heavy objects along a straight
30 line and the block (91) travels along the linear guide (90), to provide smooth motion for the
automatic surface modifying robot (50) along Y axis. The bearing support (92) is used to
provide support for a threaded shaft (89a) of the rotary actuation unit (2) with compatible
bearings, where a ball screw of the threaded shaft (89a) is rotated on the bearing support (92).
The aluminium extrusion profile (93) is positioned adjacent to the first actuator (1a), where
6
the aluminium extrusion profile (93) provides vertical support of the automatic surface
modifying robot (50).
In an embodiment, the automatic surface modifying robot (50) further comprises an electric
5 panel (6) that is positioned on the machine cabinet (4) to shield the PLC (98), HMI (14),
servo drives and other electrical components by providing an airtight enclosure for the
automatic surface modifying robot (50) that is resistant to paint fumes and water droplets. In
an embodiment, the automatic surface modifying robot (50) further comprises a bellow (8)
made from lightweight nylon material, which is positioned above the machine cabinet (4),
10 where the bellow (8) protects guideways and machine components by preventing exposure to
spray paint fumes from the spray gun (5a).
In an embodiment, the automatic surface modifying robot (50) further comprises: a
photoelectric sensor (94a) positioned near the spray gun (5a) to detect presence or absence of
15 any object at the time of spray painting using the spray gun (5a), and multiple proximity
sensors (94b), where each proximity sensor (94b) is an ultrasonic distance sensor that
positions the automatic surface modifying robot (50) parallel to a wall, and performs distance
measurement between the automatic surface modifying robot (50) and the wall. The
automatic surface modifying robot (50) also comprises a homing sensor (94c) that is
20 connected to the linear actuation unit (1) to automatically repositions the linear actuation unit
(1) and the rotary actuation unit (2) to a base position which is a home position, a safety laser
area scanner (95) to maintain safety within a safe zone (95a) of the automatic surface
modifying robot (50) and human operators, and limit switches (94c and 94d) that indicate
upper and lower limit of linear actuation unit (1).
25
In an embodiment, the automatic surface modifying robot (50) further comprises an indicator
lamp (17) that is positioned on an upper section of the machine cabinet (4), where the colour
of light elements positioned in the indicator lamp (17) indicates different levels of status of
the automatic surface modifying robot (50). In an embodiment, automatic surface modifying
30 robot (50) further comprises a homing function button connected to the homing sensor (94c)
to facilitate painting operations, where when the homing function button is activated. The
linear actuation unit (1) and the rotary actuation unit (2) are automatically brought down to
the respective base positions due to sensing from the homing sensor (94c), where the spray
gun (5a) is positioned at the base, and the linear actuation unit (1) is moved to a down home
7
position, to maintain starting positions for the painting process. In an embodiment, automatic
surface modifying robot (50) further comprises a spray visualizer (96), which includes a laser
beam arrangement that provides real-time visualization of spray spreading from the spray gun
(5a) during painting operations, where the spray visualizer (96) provides monitoring of paint
5 distribution during the painting operations.
In other words, the automatic surface modifying robot disclosed here is a mechatronic device
embedded with industrial controller (PLC), servomechanism, guided vehicle, and precise
linear balls crew mechanism. The automated painting robot is designed primarily to paints
walls. It has been designed to be able to cover a wide area (40 ft2
10 per min) and achieve
perfect finishes, whether covering walls or ceilings. The system comes with airless end
effector suitable for all kind of paints and primer. It can autonomously execute the paint job
for given floor plan with high precision maintaining the machine and human safety. The paint
robot can be controlled wirelessly via Wi-Fi enabled mobile tab. The combination of
15 components in the automatic surface modifying robot allows the device to be able to perform
many complex tasks such as autonomous navigation, spray painting, and other automated
functions. The PLC program and servomechanism provide the necessary control action for
the guided vehicle and linear ball screws allow for accurate and precise movements.
20 The automatic surface modifying robot comprises of a linear actuation, a rotary actuation, an
airless paint pump, an AMR, a human machine interface (HMI) and a Programmable logic
controller (PLC). Linear actuation refers to a ball screw mechanism for vertical reciprocating
movement. Linear actuation provides precise and consistent motion control. This is because
the end effector is programmed to move in a straight line and in a consistent speed. This
25 ensures that the paint is applied uniformly and accurately. The rotary actuation is a motorised
mechanism for the rotational movement of the end effector. This rotary actuation is designed
to move the end effector precisely and accurately at different angles with ease. It eliminates
the need for manual adjustment. The airless paint pump is a 1.2 HP brushless motor with a
displacement pump. This ensures that the painting job is even and consistent without any
30 drips or runs. Its design allows users to spray paint without having to use a compressor,
making it more efficient and easier to use. It also eliminates the need for air pressure.
The AMR is a part of the autonomous mobile robot, which is designed to make the machine
more portable and able to rotate in all directions. It can avoid obstacles in its path and is
8
programmed to follow specific paths and reach desired locations. It follows a virtual
programmable path on the floor as per the floor plan (10c and 10e). The HMI is a graphical
user interface that allows the operator to interact with the machine and control the machine's
operations. Moreover, the operator can diagnose individual electrical components, errors and
5 set machine program parameters. The PLC is the core processing unit of the machine. The
PLC controller receives input signals from sensors and then processes the data to produce the
appropriate output signals to control all the motors and servo drives. It stores all the
programs, drive parameters and synchronizes all the servo drives to provide the necessary
control action for the mobile robot. Linear ball screws allow for accurate and precise
10 movement. The automatic surface modifying robot (50) introduces a multi-program
configuration system for mobile robot control. The multi-program configuration system is
designed to store all programs, drive parameters, and synchronize servo drives to provide the
necessary control action for a automatic surface modifying robot (50). The key features of the
automatic surface modifying robot (50) include the utilization of linear ball screws, which
15 enable accurate and precise movement. In addition to the fundamental functionalities of the
automatic surface modifying robot (50), the configuration system is capable of
accommodating 51 different programs for each room. This allows for a high degree of
customization and adaptability to diverse environments. Furthermore, the system supports the
addition of multiple rooms, extending its applicability to larger spaces.
20
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The following drawings are illustrative of particular examples for enabling systems and
methods of the present disclosure, are descriptive of some of the methods and mechanism,
and are not intended to limit the scope of the invention. The drawings are not to scale (unless
25 so stated) and are intended for use in conjunction with the explanations in the following
detailed description.
FIGURES 1A-1D exemplarily illustrate perspective views and a component list of the
automatic surface modifying robot, as an embodiment of the present disclosure, wherein:
30
FIGURES 1A and 1B exemplarily illustrate front perspective views of the automatic surface
modifying robot, as an embodiment of the present disclosure.
9
FIGURE 1C exemplarily illustrates a side perspective view of the automatic surface
modifying robot, as an embodiment of the present disclosure.
FIGURE 1D exemplarily illustrates a rear perspective view of the automatic surface
5 modifying robot, as an embodiment of the present disclosure.
FIGURES 2A-2F exemplarily illustrate perspective views of the linear actuation of the
automatic surface modifying robot, as an embodiment of the present disclosure, wherein:
10 FIGURE 2A exemplarily illustrates a perspective view of the linear actuation of the
automatic surface modifying robot, as an embodiment of the present disclosure.
FIGURE 2B exemplarily illustrates a front perspective view of the top section of the linear
actuation of the automatic surface modifying robot, as an embodiment of the present
15 disclosure.
FIGURES 2C and 2D exemplarily illustrates front and side perspective views of the
automatic surface modifying robot showing the linear actuation assembly, where a section
line DD in FIGURE 2C shows is used to illustrate the internal portions in FIGURE 2D, as an
20 embodiment of the present disclosure.
FIGURE 2E exemplarily illustrates a top perspective view of the automatic surface
modifying robot showing the linear actuation assembly, as an embodiment of the present
disclosure.
25
FIGURE 2F exemplarily illustrates another top perspective view of the automatic surface
modifying robot showing the linear actuation assembly, as an embodiment of the present
disclosure.
30 FIGURE 2G exemplarily illustrates another perspective view of the automatic surface
modifying robot showing the linear actuation assembly, as an embodiment of the present
disclosure.
10
FIGURE 2H exemplarily illustrates another perspective view of the automatic surface
modifying robot showing the linear actuation assembly, as an embodiment of the present
disclosure.
5 FIGURES 3A-3C exemplarily illustrate perspective views of the rotary actuation unit of the
automatic surface modifying robot, as an embodiment of the present disclosure, wherein:
FIGURES 3A exemplarily illustrates perspective views of the rotary actuation unit of the
automatic surface modifying robot, as an embodiment of the present disclosure.
10
FIGURE 3B exemplarily illustrates a side view of the rotary actuation unit of the automatic
surface modifying robot, as an embodiment of the present disclosure.
FIGURE 3C exemplarily illustrates a front view of the rotary actuation unit of the automatic
15 surface modifying robot, as an embodiment of the present disclosure.
FIGURES 4A-4B exemplarily illustrate perspective views of the airless paint pump or the
end effector of the automatic surface modifying robot, as an embodiment of the present
disclosure.
20
FIGURE 5 exemplarily illustrates a perspective view of the machine cabinet of the automatic
surface modifying robot, as an embodiment of the present disclosure.
FIGURES 6A-6B exemplarily illustrate perspective views of the electrical panel of the
25 automatic surface modifying robot, as an embodiment of the present disclosure.
FIGURE 7 exemplarily illustrates a perspective view of the Programmable logic controller
(PLC) of the automatic surface modifying robot, as an embodiment of the present disclosure.
30 FIGURE 8 exemplarily illustrates a perspective view of the bellow of the automatic surface
modifying robot, as an embodiment of the present disclosure.
11
FIGURES 9A-9B exemplarily illustrate perspective views of the autonomous mobile robot
with omni wheel assembly of the automatic surface modifying robot, as an embodiment of
the present disclosure.
5 FIGURES 9C-19G exemplarily illustrate schematics showing the floor plan and the
programming of the autonomous mobile robot to enable it to traverse in any direction, as an
embodiment of the present disclosure.
FIGURES 10A-10B exemplarily illustrate perspective views of the guided omni wheel
10 assembly of the automatic surface modifying robot, as an embodiment of the present
disclosure.
FIGURES 11A-11C exemplarily illustrate perspective views of the driving wheel assembly
of the automatic surface modifying robot, as an embodiment of the present disclosure.
15
FIGURE 12A exemplarily illustrate perspective view of the automatic surface modifying
robot with the polishing tool as an end effector, as an embodiment of the present disclosure.
FIGURE 12B exemplarily illustrates a side perspective view with internal view of the
20 automatic surface modifying robot with the polishing tool as an end effector, as an
embodiment of the present disclosure.
FIGURE 12C exemplarily illustrates a perspective view of the polishing tool as the end
effector, as an embodiment of the present disclosure.
25
FIGURE 12D exemplarily illustrates a side perspective view of the polishing tool as the end
effector, as an embodiment of the present disclosure.
FIGURE 13 exemplarily illustrate a perspective view of the bristle strip of the automatic
30 surface modifying robot, as an embodiment of the present disclosure.
Persons skilled in the art will appreciate that elements in the figures are illustrated for
simplicity and clarity and may represent both hardware and software components of the
system. Further, the dimensions of some of the elements in the figure may be exaggerated
12
relative to other elements to help to improve understanding of various exemplary
embodiments of the present disclosure. Throughout the drawings, it should be noted that like
reference numbers are used to depict the same or similar elements, features, and structures.
5 DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments now will be described. The disclosure may, however, be embodied
in many different forms and should not be construed as limited to the embodiments set forth
herein; rather, these embodiments are provided so that this disclosure will be thorough and
10 complete, and will fully convey its scope to those skilled in the art. The terminology used in
the detailed description of the particular exemplary embodiments illustrated in the
accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to
like elements.
15 It is to be noted, however, that the reference numerals used herein illustrate only typical
embodiments of the present subject matter, and are therefore, not to be considered for
limiting of its scope, for the subject matter may admit to other equally effective
embodiments.
20 The specification may refer to “an”, “one” or “some” embodiment(s) in several locations.
This does not necessarily imply that each such reference is to the same embodiment(s), or
that the feature only applies to a single embodiment. Single features of different embodiments
may also be combined to provide other embodiments.
25 As used herein, the singular forms “a”, “an” and “the” are intended to include the plural
forms as well, unless expressly stated otherwise. It will be further understood that the terms
“includes”, “comprises”, “including” and/or “comprising” when used in this specification,
specify the presence of stated features, integers, steps, operations, elements, and/or
components, but do not preclude the presence or addition of one or more other features,
30 integers, steps, operations, elements, components, and/or groups thereof. It will be
understood that when an element is referred to as being “connected” or “coupled” to another
element, it can be directly connected or coupled to the other element or intervening elements
may be present. Furthermore, “connected” or “coupled” as used herein may include
13
operatively connected or coupled. As used herein, the term “and/or” includes any and all
combinations and arrangements of one or more of the associated listed items.
Unless otherwise defined, all terms (including technical and scientific terms) used herein
5 have the same meaning as commonly understood by one of ordinary skill in the art to which
this disclosure pertains. It will be further understood that terms, such as those defined in
commonly used dictionaries, should be interpreted as having a meaning that is consistent with
their meaning in the context of the relevant art and will not be interpreted in an idealized or
overly formal sense unless expressly so defined herein.
10
FIGURES 1A-1D exemplarily illustrate perspective views and a component list of the
automatic surface modifying robot (50), as an embodiment of the present disclosure. The
automatic surface modifying robot (50) comprises of a linear actuation (1), a rotary actuation
unit (2), an airless paint pump (3), an AMR (11), a human machine interface (HMI) (14) and
15 a Programmable logic controller (PLC) (98) [As shown in FIGURE 8]. Linear actuation (1)
refers to a ball screw mechanism for vertical reciprocating movement. More particularly, as
shown in FIGURES 1C and 1D the automatic surface modifying robot (50) comprises a
linear actuation unit (1), a rotary actuation unit (2), an end effector (5), and an omni wheel
assembly (15). The linear actuation unit (1) is mounted on a vertical frame for vertical
20 reciprocating movement and motion control of an end effector (5), where the end effector (5)
is programmed to move in a predefined line with a consistent speed. The rotary actuation unit
(2) is mechanically engaged with the linear actuation unit (1), where the rotary actuation unit
(2) moves the end effector (5) along different angles. In an example embodiment, the end
effector (5) is a spray gun (5a). The end effector (5) is equipped with a programmed
25 algorithm for consistent speed during movement, and the end effector (5) is electrically
synchronized with the rotary actuation unit (2) and the linear actuation unit (1) to control
movement of the end effector (5) along various angles. The omni wheel assembly (15) is
positioned below a machine cabinet (4) of the automatic surface modifying robot (50), which
comprises round wheels that are placed in a circular formation, so that the round wheels are
30 turnable in different directions, which allows the automatic surface modifying robot (50) to
move in all directions. In an embodiment, the vertical frame is an aluminium profile base
frame.
14
The linear actuation from the linear actuation unit (1) provides precise and consistent motion
control. This is because the end effector (5), which is a spray gun (5a), is programmed to
move in a straight line and at a consistent speed, which ensures that the paint is applied
uniformly and accurately using the spray gun (5a). The rotary actuation unit (2) is
5 mechanically engaged with the linear actuation unit (1), where the rotary actuation unit (2) is
a motorised mechanism for the rotational movement of the spray gun (5a). This rotary
actuation unit (2) is designed to move the spray gun (5a) precisely and accurately at different
angles with ease. It eliminates the need for manual adjustment. The airless paint pump (3) is a
1.2 HP brushless motor with a displacement pump. This airless paint pump (3) is designed to
10 deliver a consistent level of pressure, regardless of the type of material being sprayed. This
ensures that the painting job is even and consistent without any drips or runs. The design of
the airless paint pump (3) allows users to spray paint without need of air pressure. As an
example, the design of the airless paint pump (3) allows users to spray paint without having
to use a compressor, making it more efficient and easier to use.
15
The AMR (11) is a part of the autonomous mobile robot (102), which is designed to make the
automatic surface modifying robot (50) more portable and able to rotate in all directions. The
AMR (11) can avoid obstacles in its path and is programmed to follow specific paths and
reach desired locations. It follows a virtual programmable path on the floor as per the floor
20 plan. The HMI (14) is a graphical user interface that allows the operator to interact with the
automatic surface modifying robot (50) and control it's operations. The HMI (14) allows the
operator to connect and control the linear actuation unit (1) and the rotary actuation unit (2),
where the operator is enabled to diagnose technical condition of the automatic surface
modifying robot (50). Moreover, the operator can use the HMI (14) to diagnose individual
25 electrical components, errors and set machine program parameters. The PLC (98) is the core
processing unit of the machine.
The HMI (14) used in the automatic surface modifying robot (50) is, for example, a 7'' colour
touch screen TP 700 Comfort Panel, touch operation, 7" widescreen TFT display, 16 million
30 colours, Profinet interface, 12 MB configuration memory, and Windows CE 6.0, configurable
from WinCC Comfort V11. Human Machine Interface (HMI) (14) is a graphical user
interface that allows the operator to interact with the machine and control the machine's
operations. Moreover, the operator can diagnose individual electrical components, errors and
set machine program parameters. The PLC controller (98) receives input signals from sensors
15
and then processes the data to produce the appropriate output signals to control all the motors
and servo motors (82a and 82b). The HMI (14) stores all the programs, drive parameters and
synchronizes all the servo motors (82a and 82b) to provide the necessary control action for
the automatic surface modifying robot (50). Linear ball screws allow for accurate and precise
5 movement.
The automatic surface modifying robot (50) further comprises a teach pendant (7), which is a
component of the automatic surface modifying robot (50) that is controllable wirelessly via a
Wi-Fi enabled mobile tab. This makes it easier to move the automatic surface modifying
10 robot (50) around the painting area and allows the user to control the automatic surface
modifying robot (50) from a distance. This way, the user can adjust the settings and monitor
the paint job without having to be in the same room. The automatic surface modifying robot
(50) further comprises a solenoid actuator (87), which is an electromagnetic solenoid actuator
(87) that is used to open and close a solenoid valve (88) of the end effector (5), to precise and
15 repeatable movement of the end effector (5). As a result, the end effector (5) is precisely and
reliably triggered electrically according to the program algorithm.
The automatic surface modifying robot (50) further comprises a lifting handle (13) that is
used to shift the automatic surface modifying robot (50) from one place to other. A shock
20 absorber arrangement is also included in the automatic surface modifying robot (50), which is
a combination of springs and guide rod arrangement with linear bearings that allow the
automatic surface modifying robot (50) to be more flexible and resilient over uneven terrain,
by providing the necessary shock absorption to cope with unevenness allowing the automatic
surface modifying robot (50) to move more smoothly across the terrain. In an embodiment,
25 the servo motors (82a and 82b) facilitate absolute positioning of the automatic surface
modifying robot (50), wherein the servo motors (82a and 82b) use feedback from a position
encoder to precisely control the position, which allows servo motors (82a and 82b) to move
to a specific position, even when the motor is started and stopped multiple times.
30 The servo motors (82a and 82b) are used for precise and absolute positioning, where the
motors use feedback from a position encoder to precisely control the position. This allows
servo motors (82a and 82b) to accurately move to a specific position, even when the motor is
started and stopped multiple times. The automatic surface modifying robot (50) further
comprises a well-defined floor plan. The floor plan is a program algorithm that makes the
16
automatic surface modifying robot (50) more versatile with programmable parameters. So
that the automatic surface modifying robot (50) navigates autonomously. Parameters allow
the user to define the exact area to paint, the height of the ceiling, and the turning radius of
the automatic surface modifying robot (50), speed of the sprayer. Furthermore, programming
5 multiple rooms at once allows for faster and more efficient painting. The live status
monitoring allows the user to see how the automatic surface modifying robot (50) is
progressing and make any necessary adjustments if needed.
Referring to FIGURES 2A-2H, FIGURES 2A-2B exemplarily illustrate perspective views of
10 the linear actuation (1) of the automatic surface modifying robot (50), as an embodiment of
the present disclosure. FIGURES 2C and 2D exemplarily illustrates front and side
perspective views of the automatic surface modifying robot (50) showing the linear actuation
assembly, where a section line D-D in FIGURE 2C shows is used to illustrate the internal
portions in FIGURE 2D. FIGURE 2E exemplarily illustrates a top perspective view of the
15 automatic surface modifying robot (50) showing the linear actuation assembly. FIGURE 2F
exemplarily illustrates another top perspective view of the automatic surface modifying robot
(50) showing the linear actuation assembly. FIGURE 2G exemplarily illustrates another
perspective view of the automatic surface modifying robot (50) showing the linear actuation
assembly. FIGURE 2H also exemplarily illustrates another perspective view of the automatic
20 surface modifying robot (50) showing the linear actuation assembly, as an embodiment of the
present disclosure. In an embodiment, the linear actuation unit (1) comprises a first actuator
(1a) and a second actuator (1b) that are independent of each other, wherein the first actuator
(1a) and the second actuator (1b) functions in tandem to provide precise linear
synchronization therebetween to generate a specific motion profile of the end effector (5).
25
The linear actuation (1) works by moving an object or piece of equipment in a straight line or
moving an object extremely accurately and repeatably if required. The primary reason for
designing a linear actuator (1) into a system is for the need to move a payload in a linear
fashion. The linear actuation (1) provides precise and consistent motion control, wherein the
30 end effector (5) is programmed to move in a straight line and in a consistent speed to ensure
that the paint is applied uniformly and accurately. In an embodiment, the linear actuation (1)
of the automatic surface modifying robot (50) further comprises a ball screw and nut
assembly (89), a linear guide (90), a block (91), bearing support (92), and an aluminium
extrusion profile (93). The ball screw and nut assembly (89) translate rotational motion to
17
linear motion of the linear actuation unit (1) with reduced friction, wherein the ball screw and
nut assembly (89) comprises a threaded shaft (89a) that provides a helical raceway for ball
bearings, which is positioned in form of a precision screw. In other words, the ball screw and
nut mechanism translate rotational motion to linear motion with little friction. A threaded
5 shaft (89a) provides a helical raceway for ball bearings which act as a precision screw, where
the ball assembly acts as the nut while the threaded shaft (89a) is the screw ball screw details
are, for example, rolled ball screw of diameter 25mm and length 1350mm with end
machining lead of 5 mm.
10 The linear guide (90) of the linear actuation unit (1) includes bearings for rotary motion to
move heavy objects along a straight line. The block (91) that travels along the linear guide
(90) provides smooth motion for the automatic surface modifying robot (50) along the Y axis.
In an example, the linear motion rail and guide block for guide system used here is a linear
guide (90) that utilizes bearings, which were developed for rotary motion, to move heavy
15 objects easily in a straight line. The linear rail is the stationary component of a linear guide
(90) system. The block travels along the fixed rail, providing smooth motion along an X
and/or Y axis. Linear rails can be mounted either horizontally or vertically. The model size
used here as a width of 25 mm. The bearing support (92) is used to provide support for a
threaded shaft (89a) of the rotary actuation unit (2) with compatible bearings, where a ball
20 screw of the threaded shaft (89a) is rotated on the bearing support (92).
In this mechanism the ball screw is rotated in the two bearing supports (92). The aluminium
extrusion profile (93) is positioned adjacent to the first actuator (1a), where the aluminium
extrusion profile (93) provides vertical support of the automatic surface modifying robot (50).
25 The aluminium extrusion profile (93) is an extruded aluminium profile is used for vertical
support, for example, size of profile is heavy duty profiles 40 x 80. Aluminium profiles for
heavy loads with max stability and can absorb high dynamic loads. The servo motors (82a or
82b) for drive include, for example, a servo motor for rotate the balls crew mechanism is used
in this automatic surface modifying robot (50), which will convert the linear motion. The
30 specifications are as follows: Operating voltage 230 V 3AC Pn=0.75 kW; Nn=3000 rpm
M0=2.39 Nm; MN=2.39 Nm shaft height 40 mm incremental encoder TTL 2500 incr./rev.
with feather key and holding brake, IP65 protection with sealing ring compatible with the
converters.
18
Furthermore, different types of sensors are used in the automatic surface modifying robot
(50) that include a photoelectric sensor (94a), multiple ultrasonic proximity sensors (94b),
limit proximity sensors (94d) [FIGURE 2H], and a homing sensor (94c). The photoelectric
sensor (94a) is positioned near the spray gun (5a) for detecting presence and absence of any
5 object at the time of spray painting using the spray gun (5a). Each proximity sensor (94b) is
an ultrasonic sensor that positions the automatic surface modifying robot (50) parallel to a
wall and performs distance measurement between the automatic surface modifying robot (50)
and the wall. The homing sensor (94c) is connected to the linear actuation unit (1), where the
homing sensor (94c) automatically repositions the linear actuation unit (1) and the rotary
10 actuation unit (2) to a base position which is a home position. As shown in FIGURE 2H, the
limit proximity sensors (94d) are attached at upper and lower sections of the linear actuation
unit (1) to sense maximum displacement of the linear actuation unit (1).
As shown in FIGURES 2C and 2D, the indicator lamp (17) is positioned above the machine
15 cabinet (4) of the automatic surface modifying robot (50). The colour of the light indicates
different levels of status of the automatic surface modifying robot (50). For example, green
light indicates that the machine is running normally, yellow light means there is a warning,
and red light means the machine is in danger of overheating or malfunctioning.
This allows operator to quickly assess the status of a machine at a glance:
20 • RED: Indicates the Machine fault, Emergency stop, Drive Error.
• YELLOW: When machine is in operation.
• GREEN: Machine is ready to start.
25 The automatic surface modifying robot (50) also includes a safety laser area scanner (95) and
limit switches (94c and 94d), where the safety laser area scanner (95) maintains safety within
a safe zone (95a) of the automatic surface modifying robot (50) and human operators, and the
limit switches (94c and 94d) that indicate upper and lower limit of linear actuation unit (1).
By continuously monitoring the distance, the automatic surface modifying robot (50) uses the
30 ultrasonic sensor (94b) to adjust its speed and position to keep a safe distance, avoiding any
collisions and keeping people and equipment safe. The automatic surface modifying robot
(50) has proximity ultrasonic sensors (94b’, 94b’’, and 94b’’’) installed at different positions
above the automatic surface modifying robot (50) and also includes safety laser sensors (97’,
19
97’’, 97’’’, and 97’’’’) also positioned around the installed at different positions above the
automatic surface modifying robot (50), as shown in FIGURE 2F.
In an embodiment, the automatic surface modifying robot (50) further comprises comprising
5 a homing function button to facilitate painting operations, wherein when the homing function
button is activated, the linear actuation unit (1) and the rotary actuation unit (2) are
automatically brought down to the respective base positions, wherein the end effector (5) is
positioned at the base, and the linear actuation unit (1) is moved to the down home position,
to maintain starting positions for the painting process. In an embodiment, the automatic
10 surface modifying robot (50) further comprises a spray visualizer (96), which includes a laser
beam arrangement that provides real-time visualization of spray spreading from the end
effector (5) during painting operations, wherein the spray visualizer (96) provides monitoring
of paint distribution during the painting operations.
15 FIGURES 3A-3C exemplarily illustrate perspective views of the rotary actuation unit (2) of
the automatic surface modifying robot (50), as an embodiment of the present disclosure. The
rotary actuation unit (2) is designed using a bevel gear mechanism and servo motors (2.3),
which accurately and smoothly operate the automatic surface modifying robot (50). The
purpose of the rotary actuation unit (2) is to rotate end effector (5) within prescribed angle
20 range so that paint reaches top and bottom of wall easily. The angular Speed of this
mechanism is adjustable programmatically.
Components used in this rotary actuation unit (2) are as listed below:
• Bearing Housing (2.1), which is an Aluminium bearing housing with Bearing used
• The bearing (2.2),
25 • Servo motor (2.3), for example, Operating voltage 230 V 3AC Pn=0.2 kW; Nn=3000
rpm M0=0.64 Nm; MN=0.64 Nm; Shaft height 30 mm Incremental encoder TTL
2500 incr./rev. with feather key and holding brake, IP65 protection with sealing ring
compatible with the converters..
• Gearbox (2.4), with a gear ratio of 10:1, Frame size: 70mm with suitable for servo
30 motor.
• Solenoid coil (2.5), wherein the solenoid coil is of 24 v DC for triggering end effector.
• Bevel gear (2.6): Bevel gear with pressure angle 20 degree, Contact axis
perpendicular, 20 teeth.
20
FIGURES 4A-4B exemplarily illustrate perspective views of the airless paint pump or the
end effector (5) of the automatic surface modifying robot (50), as an embodiment of the
present disclosure. The end effector (5) is, for example, a Airless spray system Max (248
5 bar), where the atomization of coating is possible using end effectors that operate at high
pressure in airless spraying, which shortens the drying time as well as the discharge of
solvents to the atmosphere. Different types of tips are available for the end effector (5), which
allow the application of thicker house paints as well as thinner ones, such as varnish and
lacquer. Additionally, airless spray painting allows for more even pressure control and speed,
10 unless the direction is changed. Specification of gun: fluid orifice size (in) – 0.120, weight of
gun - 0.600 kg, and max fluid pressure (psi) – 3600.
The design of the airless paint pump (3) and the end effector (5) allows users to spray paint
without having to use a compressor or a can of aerosols, making it more efficient and easier
15 to use. The airless paint pump (3) also eliminates the need for air pressure,. The features of
the airless paint pump (3) include endurance chromex pump, smart control 3.0, Pro-connect,
fast-flush, easy out filter, 1.2hp brushless motor with displacement pump, and by using this
pump a user can spray paint even pressure delivery on every job. The airless paint pump (3)
also provides for increased productivity, and unmatched reliability. In an example, this
20 electrical airless sprayer unit allow to finish more tasks in a day, provides increased flow and
production rates, which often lead to improved quality of work, as well as higher levels of
efficiency.
FIGURE 5 exemplarily illustrates a perspective view of the machine cabinet (4) of the
25 automatic surface modifying robot (50), as an embodiment of the present disclosure. The
machine cabinet (4) is made of fibre reinforced polymers (FRP) composite material used for
the machine cover. It creates a strong and scratch-resistant surface that can withstand high
impacts. Furthermore, machine cabinet (4) is shock proof with 3 mm thickness. The machine
cabinet (4) is designed as per machine requirement, and the material for this cabinet is FRP
30 that is a composite material made of a polymer matrix reinforced with fibres. The fibres are
usually glass (in fibreglass), carbon (in carbon-fibre-reinforced polymer), aramid, or basalt.
The machine cabinet (4) is light in weight, having enough strength, and it protects internal
components.
21
FIGURES 6A-6B exemplarily illustrate perspective views of the electrical panel (6) of the
automatic surface modifying robot (50), as an embodiment of the present disclosure. The
automatic surface modifying robot (50) further comprises an electric panel (6) that is
positioned on the machine cabinet (4) to shield the PLC (98), HMI (14), servo drives and
5 other electrical components by providing an airtight enclosure that is resistant to paint fumes
and water droplets. The electric panel (6) is an electrical PLC (98) and servo drive panel that
is designed in a way to create an airtight enclosure for the automatic surface modifying robot
(50) that is resistant to paint fumes and water droplets. This helps to protect the internal
components from damage due to exposure to these elements. The enclosure is a type of metal
10 box which is made in size as per requirement and is typically made of mild steel with powder
coating. The back panel sheets are mounted inside the enclosure to provide structure support
for DIN rail mounting and wiring ducts.
FIGURE 7 exemplarily illustrates a perspective view of the PLC (98) of the automatic
15 surface modifying robot (50), as an embodiment of the present disclosure. The PLC (98)
Technical specifications include:, compact CPU on board I/O: 14 DI 24 V DC; 10 DO 24 V
DC; 2 AI 0-10 V DC, Power supply: DC 20.4-28.8V DC, and Program/data memory 100 KB.
In an embodiment, the automatic surface modifying robot (50) further comprises a PLC (98)
that is positioned in connection with the HMI (14), which receives input signals from sensors
20 and then processes the signals to produce output signals to control motors (81) and servo
motors (82a and 82b) that drive the linear actuation unit (1) and the rotary actuation unit (2)
and drive wheels (15a).
The PLC (98) is the core processing unit of the automatic surface modifying robot (50),
25 which receives input signals from sensors and then processes the data to produce the
appropriate output signals to control all the motors. The PLC (98) stores all the programs,
drive parameters and synchronizes all the servo motors (82a and 82b) to provide the
necessary control action for the automatic surface modifying robot (50) and linear ball screws
allow for accurate and precise movement. The program and algorithm are designed to ensure
30 that the automatic surface modifying robot (50) can operate efficiently and accurately, and
that the servo motors (82a and 82b) are able to provide the necessary control action for the
guided vehicle making it possible for the automatic surface modifying robot (50) to navigate
safely and accurately.
22
Other components associated with the servo electrical panel:
Power socket: Industrial grade 230 v panel mounted Power socket, these industrial sockets
are composed of ABS PA6 material, which makes them stable and strong for repeated and
long-term use.
5 Emergency Stop: In case of an emergency, this kill-switch will shut down the automatic
surface modifying robot (50).
Motor Drive: To control the servo motorr, an electronic amplifier used to power electric
servomechanisms. The motor drive is, for example, an Advanced motion control brushless
servo amplifier with armature connection.
10 Fan filter: is used for cooling electrical components inside the panel and restrict dust particle.
FIGURE 8 exemplarily illustrates a perspective view of the bellow (8) of the automatic
surface modifying robot (50), as an embodiment of the present disclosure. The automatic
surface modifying robot (50) further comprises a bellow (8) made from lightweight nylon
15 material, which is positioned above the machine cabinet (4), wherein the bellow (8) protects
guideways and machine components by preventing exposure to spray paint fumes. The
bellow (8) is designed to protect guideways and machine components from external damage,
and is constructed using lightweight nylon material, where such bellow covers are ideal for
fast travel applications.
20
Referring to FIGURES 9A-9B and 10A -10B, FIGURES 9A-9B exemplarily illustrate
perspective views of the autonomous mobile robot (102) of the automatic surface modifying
robot (50) showing the omni wheel assembly (15), and FIGURES 10A-10B exemplarily
illustrate perspective views of the guided omni wheel assembly (15) of the automatic surface
25 modifying robot (50), as embodiments of the present disclosure. The autonomous mobile
robot (102) is a self-driving robot that navigates and operates with the minimal human
intervention. These robots are equipped with sensors and algorithms that allow them to avoid
obstacles and safely reach their destination. As shown in FIGURES 9C-9G, the autonomous
mobile robot (102) is designed to make the automatic surface modifying robot (50) more
30 portable and able to rotate in all directions. The autonomous mobile robot (102) can avoid
obstacles in its path and can be programmed to follow specific paths and reach desired
locations. The autonomous mobile robot (102) follows a virtual programmable path on the
floor as per the floor plan. This autonomous mobile robot (102) is designed to rotate on its
own axis, hence different type of wheel combinations are used in this case. Components of
23
the autonomous mobile robot (102) include: 1. driving wheel assembly, 2. guiding omni
wheel assembly, 3. Servo motors, and 4. shock absorber arrangement.
As shown in FIGURES 10A and 10B, the wheels (15a) of the omni wheel assembly (15) are
5 used to allow the automatic surface modifying robot (50) to move in all directions. This is
accomplished by placing several small round wheels (15a) in a circular formation, so that the
wheels (15a) can turn in different directions. This allows the automatic surface modifying
robot (50) to move in any direction, even if the surface it is on is uneven. As shown in
FIGURES 9A and 9B, in an embodiment, the omni wheel assembly (15) comprises shock
10 absorbers (66) that are mounted on a connection bar (76) that is connected to the omni wheel
assembly (15), wherein the shock absorbers (66) enable seamless traversal automatic surface
modifying robot (50) on uneven surfaces. The guide assembly mainly contain omni wheel
(15a), bearing housing (15b) and spring (15c). The combination of springs (15c) and bearing
housing (15b) comprising a guide rod arrangement with linear bearings allows the automatic
15 surface modifying robot (50) to be more flexible and resilient over uneven terrain, by
providing the necessary shock absorption to cope with unevenness allowing the automatic
surface modifying robot (50) to move more smoothly across the terrain.
FIGURES 11A-11C exemplarily illustrate perspective views of the driving wheel assembly
20 of the automatic surface modifying robot (50), as an embodiment of the present disclosure.
Planetary gearboxes (6) are used for the drive wheels (15a) and the linear lifting mechanism.
In an embodiment, the automatic surface modifying robot (50) further comprises the gearbox
(6) that comprises planetary gear assembly (83) that are used to drive wheels (15a) and the
linear actuation unit (1). The planetary gear assembly (83) is composed of multiple planetary
25 gears (84) that rotate around a central sun gear (85), which is connected to an output shaft
(86a), where torque generated is transferred from an input shaft (86b) to the output shaft
(86a), providing increased torque and decreased backlash. The planetary gear design is
composed of several planetary gears that rotate around a central sun gear, which is connected
to the output shaft. This design allows for the transfer of torque from the input shaft to the
30 output shaft, while also providing increased torque and decreased backlash. For example,
drive wheel (15a) size is 200 X 50 Material –PU. Gearbox for drive includes: Size: 90, Ratio:
14, Maximum input speed: 10000 rpm, Backlash: Stage 1 (ratio 3-20): P1≤ 8 arcmin P2≤ 10
arcmin, and Noise level: ≤ 68dB, IP Grade: IP65, Life span: 20000h
24
Referring to FIGURES 12A-12D, FIGURE 12A exemplarily illustrate perspective view of
the automatic surface modifying robot (50) with the polishing tool (5b) as an end effector (5),
FIGURE 12B exemplarily illustrates a side perspective view with internal view of the
automatic surface modifying robot (50) with the polishing tool (5b) as an end effector (5),
5 FIGURE 12C exemplarily illustrates a perspective view of the polishing tool (5b) as the end
effector (5), FIGURE 12D exemplarily illustrates a side perspective view of the polishing
tool (5b) as the end effector (5). The polishing tool (5b) as the end effector (5) comprises a
first actuator (134), a second actuator (136), a third actuator (138), a polishing wheel (140), a
suction pipe (142), a dust collector unit (144). The first actuator (134) provides vertical
10 displacement of the polishing wheel (140) and the second actuator (136) provides horizontal
displacement of the polishing wheel (140), so that the polishing wheel (140) is moved across
in any direction along a steady horizontal plane. The third actuator (138) provides forward
and backward movement of the polishing wheel (140), which indicates that the first actuator
(134), the second actuator (136), the third actuator (138) working in combination provides for
15 movement of the polishing wheel (140) in X, Y and Z directions, or in a three-dimensional
coordinate system. The suction pipe (142) retrieves dust during the polishing operation and
collects the dust in the dust collector unit (144). As shown in FIGURE 12D, the polishing
tool (5b) also includes a spring suspension mechanism (146) positioned on the third actuator
(138) to compensate for the reaction force on the polishing wheel (140) when the polishing
20 wheel (140) contacts the wall surface.
Key Features:
1. 3-Axis Precision: The polishing tool (5b) is capable of state-of-the-art 3-axis system
that enables precise control over the polishing process, so that the polishing wheel (140)
25 reaches tight corners or cover larger wall surfaces.
2. Polishing Unit: The heart of this innovative tool is its high-performance polishing
unit. Equipped with advanced polishing technology, it effortlessly smooths out imperfections,
blemishes, and uneven surfaces on your walls.
3. The dust collector unit (144) is provided since cleanliness is essential during any
30 home improvement project. The polishing tool (5b) is equipped with an efficient dust
collector that captures and contains dust particles generated during the polishing process.
This helps workers to breathe easy and maintain a clean work environment during the
polishing process of the walls.
25
4. The polishing tool (5b) has a user-friendly design, where the end effector is designed
with ease of use in mind. The polishing tool (5b) is lightweight, ergonomic, and intuitive to
operate, reducing operator fatigue and ensuring a comfortable grip for extended use.
5. Versatile Applications: The polishing tool (5b) is versatile and adaptable to various
5 wall types, including drywall, plaster, concrete, and more. It's suitable for both residential and
commercial projects.
6. Quality Craftsmanship: Crafted from durable materials, the polishing tool (5b) is built
to last. It can withstand the rigors of daily use and provide reliable performance for years to
come.
10
FIGURE 13 exemplarily illustrate a perspective view of the bristle strip of the automatic
surface modifying robot (50), as an embodiment of the present disclosure. The bristle strip
acts as a filter and traps the paint fumes before they can enter the machine and cause damage.
It also prevents the paint from entering the machinery and potentially clogging the internal
15 components.
The automated painting robot that paints walls and has been designed to be able to cover a
wide area (40 ft2
per min) and achieve perfect finishes, whether covering walls or ceilings.
The system comes with airless end effector suitable for all kind of paints and primer. It can
20 autonomously execute the paint job for given floor plan with high precision maintaining the
machine and human safety. This automated painting robot is designed to paint walls up to a
height of 3.2 meters. This enables the robot to reach higher areas on the wall and to work at a
quicker rate than a manual painter. This is because it can move more quickly in a more
precise manner.
25
The paint robot can be controlled wirelessly via a Wi-Fi enabled mobile tab. This makes it
easier to move the robot around the painting area and allows the user to control the robot
from a distance. This way, the user can adjust the settings and monitor the paint job without
having to be in the same room. At the beginning, the machine must be manually aligned to
30 the floor plan's start point. It is similar to a car that needs to be aligned before it can be driven
once that initial step is done, the machine can take care of the rest.
Current invention has been discussed specifically with full disclosure. However, numerous
changes can be made in the detail of structures, combinations, and part arrangement along
26
with technical advancements that will be implemented in near future without changing the
spirit and scope of the invention.
Although the invention has been described with reference to specific embodiments, this
5 description is not meant to be construed in a limiting sense. Various modifications of the
disclosed embodiments, as well as alternate embodiments of the invention, will become
apparent to persons skilled in the art upon reference to the description of the invention. It is
therefore, contemplated that such modifications can be made without departing from the
scope of the present invention as defined.
27
We Claim:
1. An automatic surface modifying robot (50) comprises:
5 a linear actuation unit (1) mounted on a vertical frame for vertical reciprocating
movement and motion control of an end effector (5), wherein the end effector (5) is
programmed to move in a predefined line with a consistent speed;
a rotary actuation unit (2) that is mechanically engaged with the linear actuation unit
(1), wherein the rotary actuation unit (2) moves the end effector (5) along different angles;
10 wherein the end effector (5) which is equipped with a programmed algorithm for
consistent speed during movement, wherein the end effector (5) is electrically synchronized
with the rotary actuation unit (2) and the linear actuation unit (1) to control movement of the
end effector (5) along the different angles; and
an omni wheel assembly (15) that is positioned below a machine cabinet (4) of the
15 automatic surface modifying robot (50), wherein the omni wheel assembly (15) comprises
round wheels that are placed in a circular formation, so that the round wheels are turnable in
different directions, which allows the automatic surface modifying robot (50) to move in all
directions.
20 2. The automatic surface modifying robot (50) as claimed in claim 1, wherein the
vertical frame is an aluminium profile base frame.
3. The automatic surface modifying robot (50) as claimed in claim 1, wherein the linear
actuation unit (1) comprises a first actuator (1a) and a second actuator (1b) that are
25 independent of each other, wherein the first actuator (1a) and the second actuator (1b)
functions in tandem to provide precise linear synchronization therebetween to generate a
specific motion profile of the end effector (5).
4. The automatic surface modifying robot (50) as claimed in claim 1, wherein the rotary
30 actuation unit (2) comprises:
a bearing housing (2.1) that is made of aluminium;
a bearing (2.2) that is positioned within the bearing housing (2.1);
a servo motor (2.3) positioned in the bearing housing (2.1) to provide incremental
movement of the rotary actuation unit (2);
28
a gearbox (2.4) with a gear ratio 10:1 for working of the motor;
a solenoid coil (2.5) for triggering of the end effector (5); and
a bevel gear (2.6) with a pressure angle of 20 degrees, comprising a perpendicular
contact axis.
5
5. The automatic surface modifying robot (50) as claimed in claim 1, further comprising
a human machine interface HMI (14), which is a graphical user interface that allows an
operator to connect and control the linear actuation unit (1) and the rotary actuation unit (2),
wherein the operator is enabled to diagnose technical condition of the automatic surface
10 modifying robot (50).
6. The automatic surface modifying robot (50) as claimed in claim 4, further comprising
a PLC (98) that is positioned in communication with the HMI (14), which receives input
signals from sensors (94a, 94b, and 94c) and then processes the signals to produce output
15 signals to a control motor (81) and servo motors (82a and 82b) that drive the linear actuation
unit (1) and the rotary actuation unit (2) and drive wheels (15a).
7. The automatic surface modifying robot (50) as claimed in claim 1, wherein the
machine cabinet (4) is positioned at a lower section along the vertical frame, wherein the
20 machine cabinet (4) is made of fibre reinforced polymer (FRP) composite material.
8. The automatic surface modifying robot (50) as claimed in claim 1, wherein the omni
wheel assembly (15) comprises shock absorbers (66) that are mounted on a connection bar
(76) that is connected to the omni wheel assembly (15), wherein the shock absorbers (66)
25 enable seamless traversal of the automatic surface modifying robot (50) on uneven surfaces.
9. The automatic surface modifying robot (50) as claimed in claim 1, wherein the end
effector (5) is one of a spray gun (5a) and a polishing tool (5b).
30 10. The automatic surface modifying robot (50) as claimed in claim 8, further comprising
an airless paint pump (3) that is connected to the spray gun (5a), wherein the airless paint
pump (3) delivers a consistent level of pressure, regardless of type of paint material that is
sprayed, and provides a consistent paint job without any drips and runs, and wherein the
design of the airless paint pump (3) allows users to spray paint without need of air pressure.
29
11. The automatic surface modifying robot (50) as claimed in claim 1, further comprising
an autonomous mobile robot (AMR) (11), which is designed to make the automatic surface
modifying robot (50) more portable and rotatable in all directions, wherein the AMR (11)
5 prevents the automatic surface modifying robot (50) from obstacles along different paths that
the automatic surface modifying robot (50) is programmed to follow to reach predefined
locations, and wherein the AMR (11) follows a virtual programmable path on floor as per a
floor plan.
10 12. The automatic surface modifying robot (50) as claimed in claim 1, further comprising
a gearbox (6) that comprises planetary gear assembly (83) that are used to drive wheels (15a)
and the linear actuation unit (1), wherein the planetary gear assembly (83) is composed of a
plurality of planetary gears (84) that rotate around a central sun gear (85), which is connected
to an output shaft (86a), wherein torque generated is transferred from an input shaft (86b) to
15 the output shaft (86a), providing increased torque and decreased backlash.
13. The automatic surface modifying robot (50) as claimed in claim 1, further comprising
a teach pendant (7), which is positioned at a front section of the automatic surface modifying
robot (50), which is controllable wirelessly via a Wi-Fi enabled mobile tab, wherein the teach
20 pendant (7) allows a user to control the automatic surface modifying robot (50) from a
distance.
14. The automatic surface modifying robot (50) as claimed in claim 1, further comprising
a solenoid actuator (87), which is electromagnetic solenoid actuator (87) that is used to open
25 and close a solenoid valve (88) of the end effector (5), to precise and repeatable movement of
the end effector (5).
15. The automatic surface modifying robot (50) as claimed in claim 6, wherein the servo
motors (82a and 82b) provide absolute positioning of the automatic surface modifying robot
30 (50), wherein the servo motors (82a and 82b) use feedback from a position encoder to
precisely control the position, which allows servo motors (82a and 82b) to move to a specific
position, even when the control motor (81) is started and stopped multiple times.
30
16. The automatic surface modifying robot (50) as claimed in claim 1, wherein the linear
actuation unit (1) comprises:
a ball screw and nut assembly (89) to translate rotational motion to linear motion of
the linear actuation unit (1) with reduced friction, wherein the ball screw and nut assembly
5 (89) comprises a threaded shaft (89a) that provides a helical raceway for ball bearings, which
is positioned in form of a precision screw;
a linear guide (90) of the linear actuation unit (1) that includes bearings for rotary
motion to move heavy objects along a straight line;
a block (91) that travels along the linear guide (90), to provide smooth motion for
10 the automatic surface modifying robot (50) along Y axis;
a bearing support (92) that is used to provide support for a threaded shaft (89a) of
the rotary actuation unit (2) with compatible bearings, wherein a ball screw of the threaded
shaft (89a) is rotated on the bearing support (92); and
an aluminium extrusion profile (93) that is positioned adjacent to the first actuator
15 (1a), wherein the aluminium extrusion profile (93) provides vertical support of the automatic
surface modifying robot (50).
17. The automatic surface modifying robot (50) as claimed in claim 9, further comprising
an electric panel (6) that is positioned on the machine cabinet (4) to shield the PLC (98), HMI
20 (14), servo motors (82a and 82b) and other electrical components by providing an airtight
enclosure for the automatic surface modifying robot (50) that is resistant to paint fumes and
water droplets.
18. The automatic surface modifying robot (50) as claimed in claim 9, further comprising
25 a bellow (8) made from lightweight nylon material, which is positioned above the machine
cabinet (4), wherein the bellow (8) protects guideways and machine components by
preventing exposure to spray paint fumes from the spray gun (5a).
19. The automatic surface modifying robot (50) as claimed in claim 9, further comprising:
30 a photoelectric sensor (94a) positioned near the spray gun (5a) for detecting presence
and absence of any object at the time of spray painting using the spray gun (5a),
a plurality of proximity sensors (94b), wherein each proximity sensor (94b) is an
ultrasonic sensor that positions the automatic surface modifying robot (50) parallel to a wall,
31
and performs distance measurement between the automatic surface modifying robot (50) and
the wall,
a homing sensor (94c) that is connected to the linear actuation unit (1), wherein the
homing sensor (94c) automatically repositions the linear actuation unit (1) and the rotary
5 actuation unit (2) to a base position which is a home position,
a safety laser area scanner (95) to maintain safety within a safe zone (95a) of the
automatic surface modifying robot (50) and human operators, and
a set of limit switches (94c and 94d) that indicate upper and lower limit of linear
actuation unit (1).
10
20. The automatic surface modifying robot (50) as claimed in claim 1, further comprising
an indicator lamp (17) that is positioned on an upper section of the machine cabinet (4),
wherein the colour of light elements positioned in the indicator lamp (17) indicates different
levels of status of the automatic surface modifying robot (50).
15
21. The automatic surface modifying robot (50) as claimed in claim 9, further comprising
a homing function button connected to the homing sensor (94c) to facilitate painting
operations, wherein when the homing function button is activated, the linear actuation unit
(1) and the rotary actuation unit (2) are automatically brought down to the respective base
20 positions due to sensing from the homing sensor (94c), wherein the spray gun (5a) is
positioned at the base, and the linear actuation unit (1) is moved to a down home position, to
maintain starting positions for the painting process.
22. The automatic surface modifying robot (50) as claimed in claim 9, further comprising
25 a spray visualizer (96), which includes a laser beam arrangement that provides real-time
visualization of spray spreading from the spray gun (5a) during painting operations, wherein
the spray visualizer (96) provides monitoring of paint distribution during the painting
operations.