Immersion coating method utilizing multiple curing workstations

Abstract

A coating system includes a plurality of liquid immersion workstations positioned along an arcuate path, the plurality of liquid immersion workstations defining a single complete coating process for a sequence of objects. A plurality of curing workstations are configured to independently receive objects of the sequence of objects exiting the plurality of liquid immersion workstations. An articulated robotic arm has a base positioned inside the arcuate path in top plan view such that the robotic arm is operable to carry each object of the sequence of objects through each of the plurality of liquid immersion workstations and to exactly one of the plurality of curing workstations. An articulated robotic hand is provided at a distal end of the robotic arm and configured to grasp and hold each of the objects and to oscillate the object while submerged in each of the plurality of liquid immersion workstations.

What is claimed is: 
     
         1 . A method of processing objects through a coating system, the method comprising:
 providing a plurality of liquid immersion workstations, each having a liquid immersion tank associated with a coating process, the plurality of liquid immersion workstations arranged along an arcuate path;   carrying a first one of the objects with an articulated robotic arm through the plurality of liquid immersion workstations along the arcuate path, and articulating the robotic arm at each of the plurality of liquid immersion workstations to immerse and subsequently lift the first object;   articulating a robotic hand at a distal end of the robotic arm to oscillate the first object while the robotic arm holds the first object immersed in the liquid of the liquid immersion tank of each of the plurality of liquid immersion workstations;   delivering the first object from a final one of the plurality of liquid immersion workstations into a first curing workstation using the robotic arm;   carrying a second one of the objects with the robotic arm through the plurality of liquid immersion workstations along the arcuate path, and articulating the robotic arm at each of the plurality of liquid immersion workstations to immerse and subsequently lift the second object;   articulating the robotic hand to oscillate the second object while the robotic arm holds the second object immersed in the liquid of the liquid immersion tank of each of the plurality of liquid immersion workstations; and   delivering the second object from the final one of the plurality of liquid immersion workstations into a second curing workstation using the robotic arm, while the first object remains in the first curing workstation.   
     
     
         2 . The method of  claim 1 , wherein the steps of articulating the robotic hand to oscillate the first and second objects includes in each case articulating a wrist joint about multiple degrees of freedom. 
     
     
         3 . The method of  claim 1 , further comprising simultaneously curing a coating applied to the first object in the first curing workstation and curing a coating applied to the second object in the second curing workstation during processing of at least one additional object through the plurality of liquid immersion workstations, following delivery of the second object to the second curing workstation. 
     
     
         4 . The method of  claim 1 , wherein the robotic arm engages the first object at a loading zone positioned at an upstream end of the arcuate path adjacent a first one of the plurality of liquid immersion workstations, and wherein the robotic arm maintains custody of the first object until delivered into the first curing workstation. 
     
     
         5 . The method of  claim 1 , wherein the coating process is an e-coat process, the plurality of liquid immersion workstations including, in order: clean, rinse, conversion coat, rinse, e-coat, and post rinse workstations. 
     
     
         6 . The method of  claim 1 , wherein carrying the first object with the robotic arm through the plurality of liquid immersion workstations includes covering at least a 90-degree span about a first axis on which the arcuate path is centered.