Automated wrapping of components in transport structures

The present disclosure relates generally to vehicles and other transport structures such as trucks, tractors, busses, trains, sea vessels, aircraft and spacecraft, and more specifically to automated techniques for wrapping vehicle components.

Conventional approaches to enhancing the aesthetic effect of a transport structure such as a vehicle include painting. Painting can be expensive, and is not environmentally friendly. Hand-wrapping, which involves wrapping exterior vehicle panels with commercial off the shelf (COTS) wrap materials available in various colors, is commonly performed over a painted vehicle for customization. Hand-wrapping can also be used as an alternative to painting. For example, a vehicle may be taken to a body shop where the surface of the vehicle is manually wrapped to provide a different base color. In this case, the vehicle is already assembled. It is ordinarily impractical and expensive to disassemble the vehicle to apply wrapping to individual parts. Thus, the wrapping is conventionally applied on the outer surfaces, with the wrapping folded and trimmed around door edges and other areas in a best attempt to achieve an acceptable fit.

Several aspects will be described more fully hereinafter with reference to various illustrative aspects of the present disclosure.

In one aspect of the disclosure, an apparatus for automated film wrapping of vehicle components includes a grabber arm mounted to a base at a first end and configured to grab a length of film from a feed roll and position the length of film over a vehicle component to be wrapped, a fixture configured to secure the vehicle component such that an exterior portion of the vehicle component faces the film, and an actuator coupled to the fixture and configured to controllably push the vehicle component into the film until the exterior portion is at least partially wrapped therein.

In another aspect of the disclosure, a system for automated film wrapping includes a first station including a grabber arm mounted to a base at a first end and configured to grab a length of film from a feed roll and drag the film into a position over a component to be wrapped, a fixture configured to secure the component and an actuator coupled to the fixture and configured to controllably push an exterior portion of the vehicle component into the film until the exterior portion is at least partially wrapped therewith.

In yet another aspect of the disclosure, a method for automated film wrapping includes grabbing, by an automated grabber arm, a length of film from a feed roll, dragging, by the automated grabber arm, the film into a position over the vehicle component to be wrapped, securing a component onto a fixture such that an exterior portion of the component faces the film, and controllably pushing, by an actuator coupled to the fixture, the component upward into the film until the exterior portion is at least partially wrapped therein.

It will be understood that other aspects of the disclosure will become readily apparent to those skilled in the art based on the following detailed description, wherein they are shown and described in only several embodiments by way of illustration. As will be appreciated by those skilled in the art, these vehicles, structures and techniques can be realized with other embodiments without departing from the spirit and scope of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

The detailed description set forth below in connection with the drawings is intended to provide a description of exemplary embodiments of the present invention. The description is not intended to represent the only embodiments in which the invention may be practiced. The terms “exemplary” and “example” used throughout this disclosure mean “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or may be shown not drawn to scale, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.

An automated technique for the custom wrapping of vehicle components is presented to meet a variety of objectives and applications. An objective is to apply an aesthetic film surface to vehicle exterior and interior components utilizing COTS films for the process. Apart from improved aesthetics, these films may offer advanced UV protection and protective layers and/or coatings to significantly improve resistance to adverse environmental factors.

Among numerous other applications in the aftermarket and otherwise, the automated wrapping techniques as described have utility in the context of OEMs applying wrapping to parts that have yet to be assembled. This pre-assembly stage can enable the wrapping to be ideally achieved in a high quality manner, exploiting the flexibility associated with individual wrapping of components free from the confines of interconnected parts.

These films may be developed to have extended life to meet OEM specifications and customer expectations. The subject matter in this disclosure additionally may make it possible to wrap complex part geometries with the intent of limiting exposure to sunlight. For example, parts may be designed in a manner such that they have a lower proportion of horizontal surfaces otherwise having exposure areas to sunlight.

One aspect of an automated wrapping mechanism may include a grabber arm to extend the wrap and remove the backing, a movable fixture to secure a component and present it to the extended wrap, an actuator to move the component, via the fixture, into the wrap, and an applicator to secure the wrap to the component.

FIG. 1 is a side view of an automated vehicle wrapping mechanism 100 in accordance with an embodiment. A component 108, such as a vehicle panel, may be secured onto a fixture mechanism 110, which may in turn be coupled to an actuator 126 of wrapper mechanism 100. The component 108 may be automatedly wrapped in response to controller commands using the automated wrapping mechanism 100. A standard material feed roll 106 may provide film/wrap material for the automated wrapping process.

In one aspect, the wrapping mechanism 100 includes a grabber arm 102 having a first end suspended from or otherwise mounted on a base 115a for handling the wrap roll 106. The grabber arm 102 is initially shown at a start position. The grabber arm picks up the film 107a and travels to a final position as shown. In traveling from the start position to the final position, the grabber arm extends the film 107a in an arc-like direction or other orientation to spread the film 107a relative to the component 108, thereby enveloping the part.

The grabber arm 102 may also remove the backing layer from the B-side of the wrap portion, e.g., using one or more tension rollers, thus preparing the wrap 107a for application as a film over the component. Wrap and film are herein used interchangeably.

As an example of these operations, the material feed may be controlled with tension rollers that control film (wrap) tension and remove backing from the film material. The grabber arm 102 may grab the end of the material 107a and drag it across the part 108 while controlling the tension of film to be applied. In other configurations, a separate tension roller or other device may be used to remove the backing from the wrap. In still other embodiments, more than one robotic arm is used to conduct one or more of the above operations.

In FIG. 1, wrap 107a is shown at an initial time t when the wrap is first taken from the roll 106, and wrap 107b shows the same spread wrap later at time t+x being applied onto the component 108.

The base 115a from which the grabber arm is suspended or mounted includes a common structural framework that extends to other devices in the wrapping mechanism 100. The structural framework may have an operating envelope defined by the travel capability of the arm in one or more directions. The parts to be wrapped may be those that are identified to fit within this envelope.

Further, while grabber arm 102 is shown as traveling in two positions, the grabber arm 102 may enjoy additional degrees of freedom and may move in more complex ways as necessary to accomplish the wrapping. The grabber arm 102 may utilize one or more appropriate effectors at a second end to handle the film during the wrapping operation. The effectors may be interchangeable. The grabber arm 102 may be telescopic in nature, such that the length and radii of the grabber arm 102 can be adjusted as the part 108 is wrapped.

A central control system may provide operating instructions to the grabber arm 102 and other devices. The central control system may include a synchronized controller 117 or processing system with one or more processors for executing the code that controls the grabber arm 102 and wrapping mechanism 100 in general, and memory to store the code. The fixture, actuator, grabber arm, hemming arm, cutting arm and other systems may be connected to a common structural framework via the base. (In other embodiments, a single arm may use one or more of a grabbing, cutting, or hemming effector per controller instruction.) The controller may provide information to the various systems based on part-specific programming, which may include pressure data for the actuators, applicators and components to be wrapped. Programmed code specific to the part being wrapped may take into account the part's properties and geometry, and may execute instructions based on this known information. Different applications corresponding to different part types can make the wrapping process highly efficient and amenable for use in a mass assembly setting, in contrast to conventional hand-wrapping techniques.

A component 108 to be wrapped may include an exterior surface or “A-side” 113 intended for assembly on an external portion of a transport structure. The hand-wrapping mechanism 100 may, however, be equally applicable to interior components where such use is desired. A custom fixture mechanism 110 may be used to handle the component 108 to be wrapped and to orient the component 108 (e.g., keep the component in a lowered position with the exterior surface facing upward) while the grabber arm(s) maintain the extended wrap 107b over the component.

The fixture 110 may be configured to properly support a specific type of component. The fixture 110, using an actuator mechanism as described below, may raise the component 108, e.g., upward toward the extended wrap 107a until the wrap contacts the exterior surface 113 and the wrap's adhesive B-side begins to adhere to the surface 113. At this point, the actuator 126 may continue applying gentle pressure until the initial wrap is substantially complete. In some embodiments, the actuator 126 may additionally or alternatively move the fixture 110 in one or more directions under controller command in order to facilitate an accurate and complete wrap. For example, the actuator 126 may move the component 108 sideways momentarily to enable the relevant side of the exterior portion 113 to more fully adhere to the wrap 107b.

The actuator 126 may alternatively move the fixture 110 to expose the component 108 in a manner that enables the grabber arm 102 in conjunction with an applicator 104, to perform more of the overall work in securing the wrap 107b over the component's exterior surface 113. The actuator 126 and grabber arm 102 may be cross-coupled to move based on feedback received from each other or they may otherwise be collectively coordinated under central command of the controller 117 to perform the wrapping in as efficiently and accurately a manner as possible.

The grabber arm 102 may be coupled to the applicator 104 via a common structural framework such as base 115b and/or 115c. The connection may be direct or indirect, e.g., through intermediary structures. The applicator may work in coordination with the actuator 126 or grabber arm 102 to apply downward pressure on the exterior surface 113 of the wrap 107b to smooth the wrap and expel trapped air. Motion of the grabber arm 102 and the applicator 104 can be coordinated in some embodiments, such that the applicator is instructed to activate at a certain time or in a certain position of component 108 or fixture 110.

In an embodiment, the applicator 104 may be a spherical roller, which may include an extendable arm 104a with a spherical rotating ball 104 at the end. The rotating ball 104 may move across the wrap 107b over the exterior surface 113 to compress the wrap 107b until it conforms to the shape of the component 108, thereby securing the wrap to the component 108. In other embodiments, the applicator function may be accomplished by a flat press or other actuator mechanism having a different shape and structure. As shown by the vertical arrows adjacent extendable arm 104a, the applicator may move up or down responsive to commands from the controller. Other directions are possible for more sophisticated applicators.

The applicator 104 may in various embodiments be fully or partially automated and may act in response to feedback from the controller. These movements and actions may be provide via controller instructions based on the type of part to be wrapped by the film. Various degrees of freedom of the applicator 104 may be used to perform the wrapping process depending on the complexity of the part.

In alternative embodiments, the applicator 104 may be structurally independent from other devices, and may employ a manual or hand-held roller. In an embodiment, a manual operation is performed in the wrapping process in which an operator uses a tool (such as a spherical hand-held roller) to ensure that the film conforms to the shape of the part without trapped air.

In an embodiment, automation is used to drive the wrapping process wherein parts with complex geometries are wrapped with the film. Instead of mechanical pressure delivered by the applicator 104 as illustrated in FIG. 1, pneumatic pressure (heat jet stream) may be used to wrap the film. The air used in this process may be heated such that its temperature is higher than the ambient temperature. The heated air may be provided directly by the applicator 104 (e.g., through a dedicated channel originating at the base 115b and terminating near the end of the applicator 104) or separately by another structure.

In some embodiments, the applicator 104 itself may be heated as well. In a fully automated embodiment, the wrapping operation may be performed in a controlled environment such as a structural chamber that encompasses bases 115a-c and the remaining equipment, wherein the ambient temperature of the environment may be elevated in a controlled manner to increase the quality of the wrapping.

In an embodiment, bespoke fixtures (e.g., fixture 110) are tailored to the parts being wrapped, and are implemented with a common fixture actuation mechanism 126. The fixture 110 can move upward and downward vertically in a one-axis (z) configuration as illustrated by the adjacent vertical arrows. The fixture 110 may be moved by actuator 126, for example, in an up-down configuration as shown by the vertical arrows adjacent fixture 110. Actuator 126 may be coupled to a common framework of the base 115c such that, in various embodiments, the actuator 126 can be configured to operate in concert with grabber arm 102 and applicator 104.

The actuator 126 may in some embodiments be configured to move the fixture 110 using additional degrees of freedom beyond the vertical (up-down) movement, as shown by the curved arrows adjacent actuator 126. In other embodiments, actuator 126 may be configured to rotate, as illustrated by the perspective circular arrow surrounding actuator 126. Using these additional degrees of freedom, the actuator 126 may orient the fixture 110 and hence the component 108 in different ways relative to the wrap 107a-b to help optimally secure the wrap 107a-b onto the component. These additional degrees of freedom can add significant functional flexibility to the wrapping mechanism 100 and can increase the integrity of the wrap. These additional degrees of freedom are especially helpful when wrapping complex geometries that may lack the smooth horizontal surfaces found on many panels. For more complex parts, the fixture could actuate about 2-axes, 3-axes or 5-axes. In an alternative embodiment, this actuation process may be automated, and would be coupled with the actuation of the top roller.

In some embodiments, the fixture 110 is operatively coupled to the applicator 104 so that the two actuating mechanisms can coordinate their respective movements to maintain an even pressure on the component 108, which can further increase accuracy and efficiency of the wrap. Thus, for example, if the applicator/roller 104 comes down to compress the part, the fixture 110 may move up to increase the compressive force. In an embodiment, these actuators may be fully automated while being operatively coupled under control of controller 117 or processor unit, all acting under the common structural framework of bases 115b-c. The controller 117 may additionally or alternatively be hardware based, in part or in whole, and may include digital signal processors and other dedicated hardware to provide commands and feedback to various portions of the wrapping mechanism. Fixtures and applicators having a wide variety of different structural and functional features may be designed for use with the controller for full automation. Different fixtures and applicators may be used for different types of components (which may include within its scope any component having one or more exterior surfaces for which wrapping is desired).

In some embodiments, the panel or other component is oriented properly and connected to the fixture 110 first, after which the component/fixture assembly is connected to the actuation mechanism 126. In an embodiment, the actuator 126 may be under manual control, either alone or with additional structures such as levers to raise the fixture 110.

The fixture 110 may be actuated to push the part into the film in a controlled manner. The applicator 104, e.g., the opposing spherical roller, may follow the contour of the part on the exterior surface 113 ensuring removal of any trapped air. The action of the applicator 104 may be coordinated with the actuator 126 acting on the fixture 110 to ensure that predetermined pressure is applied across the surface of the part 108. Manual (e.g., visual) or automated confirmation may be used to ensure that the region between the film and the part being wrapped is fully evacuated, as trapped air diminishes the aesthetic and mechanical properties of the film covering. The film bond can also fail because of trapped air.

In a related aspect of the disclosure, use of a wrapping mechanism is based on wrapping separate components to support production build processes, serviceability and reparability.

Once the part 108 is fully draped using any one or more of the embodiments described above, a cutting mechanism may traverse all around the part to ensure that the film is trimmed across all the edges, and the process returns to its original state, e.g., ready for the next wrapping process (or alternatively, ready for a hemming process). In various embodiments, the grabber arm can include a blade/cutting effector to perform the cutting operation. In some embodiments, the common structural framework of bases 115a and 115c, together with the controller 117, can provide more sophisticated movement to provide additional degrees of freedom to the operation. For example, a combination of the fixture 110 movement and the grabber/cutter arm (e.g., grabber arm 102 using a blade effector, or another arm dedicated to cutting) movement can result in a coordinated movement to perform a precise wrapping and cutting operation.

FIG. 2 is a side view of an automated vehicle hemming mechanism 200 in accordance with an embodiment. Following wrapping, a hemming operation may be employed to seal the edge of the wrap 202a around a respective edge of the component 208 using the fixture 210 and a soft hemming arm 231. The fixture 210 may be an identical fixture 110 as above, or the component 208 may be hemmed using different instruments, e.g., located at a dedicated hemming station to which a component is transported after the initial wrap. In an exemplary embodiment, the wrapping and hemming mechanisms are identical except that an additional arm (hem arm 231) is employed. Alternatively, after wrapping, grabber arm 102 may change effectors to one suitable for hemming. The hemming process may be manual or automated. The fixture 210 holding the part 208 to be wrapped may be used in both the wrapping and hemming operations by having acceptors configured to receive the same fixture.

In an embodiment, the hemming operation is automated. The fixture 210 supports the component. In an exemplary embodiment, a soft hemming arm 231 with a pressure-controlled end effector would traverse along the periphery of the part and hem the wrap edge 202a to an interior side of the component edge. In various embodiments, the wrap edge 202a is treated with another agent or adhesive to securably affix the wrap edge 202a to the component. In other embodiments, the end effector 206 simply applies pressure to the wrap edge 202a and adjacent areas of the swap 202 to achieve the hemming.

In an embodiment, the hemming arm 231 is mounted to a portion of the base 215d. Base 215d may be equivalent to the base 115a such that the hemming arm is mounted adjacent grabber arm 102. In embodiments where the hemming station is a physically distinct station, the hemming station may have its own controller 217, or it may be networked to receive instructions from controller 117 at a wrapping station for optimizing efficiency, or both.

During the hem, the component 208 is secured by fixture 210, which may be moved on the fly by the actuator 226 to ensure ideal positioning. In various embodiments, the hemming arm 231 is a five axis arm, in which case the hemming arm 231 can move upward, downward, and side-to-side, and can also rotate about its longitudinal axis. This freedom of movement of the end effector 206, along with the ability of actuator 226 to mobilize component 208 via fixture 210, enables the end effector 206 to be positioned very precisely based on instructions from controller 217 for highly accurate hems.

In still additional embodiments that may be especially suitable for more complex parts, the fixture actuation (see FIG. 1) and hemming arm actuation may be operably coupled. This coupling may also enable an integrated wrap/hem mechanism to wrap and hem concurrently. For example, a portion of the wrap that is complete may undergo processes of cutting and hemming, while the remainder of the wrap is secured to the component using the actuator 126 and applicator 104. In another embodiment, the hem is coordinated with the cut so that the wrapped part can be cut and hemmed simultaneously.

While panels of transport structures represent common examples of components for which wrapping is desired, the present disclosure is not so limited and essentially any component having an exterior portion or requiring a film akin to wrapping as described herein may be candidates for wrapping. Additionally, applications targeted specifically to optimizing the wrapping process for these complex components can be programmed into the controller. With the automated systems, ever more complex and geometrically diverse parts can become candidates for accurate and efficient wrapping.

FIG. 3 is a flow diagram illustrating a method for wrapping a vehicle component in accordance with an embodiment. The component is secured onto the fixture to be used such that the exterior portion of the component faces the film (302). If necessary, the fixture is secured onto the actuator. Thereupon, the controller initiates the activity of the grabber arm, which grabs a length of film (wrap) from a feed roll (304). The grabber arm drags the film into position over the component mounted on the fixture (306). Next, the actuator controllably pushes the component into the film via the fixture until the exterior portion is at least partially wrapped with the film (308). An applicator may concurrently provide pressure to an opposite side of the film to remove trapped air. The wrapped film is then cut around the periphery of the component by the grabber arm or by a separate cutting mechanism (310). The film is then hemmed, by the same machine or, in some embodiments, at another station (312).

The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to the exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other solar vehicles and for techniques for additively manufacturing structures within solar vehicles. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure, but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”