168 of a first roll 170 of the plurality of paint film rolls 138 from the film positioning device 134. A first end 172 of the paint film 168 extends through the first clamp 160 to the second clamp 164 while the second clamp 164 is in the first clamp position. The second clamp 164 is configured to receive the first end 172 of the first roll 170 and clamp the first end 172. The second clamp 164 transitions from the first clamp position to the second clamp position to thereby move the paint film 168 across the film adhering device 132 and unroll the first roll 170. The first clamp 160 is configured to clamp the paint film 168 when the second clamp 164 is in the second clamp position.

A component 180 may be disposed in a first portion 182 of the vacuum sealed chamber 156 and positioned between the paint film 168 and the first housing 152. Examples of the component 180 include panels of a vehicle, such as a side view mirror panel, a door panel, a hood panel, a liftgate panel, and another suitable panel. The component 180 may also be a non-automotive component. The component 180 may be positioned on a component stand 184. The component stand 184 is attached to and disposed within the first housing 152. The component stand 184 is movable between a first stand position and a second stand position using a second actuator (e.g., second actuator 116), based on input from the control module. When the component stand 184 is in the first stand position (shown in solid lines in FIG. 2), the component 180 is spaced from the paint film 168. When the component stand 184 is in the second stand position (shown in phantom lines in FIG. 2), the component 180 is pressed into the paint film 168. As the component stand 184 transitions from the first stand position to the second stand position, the component stand 184 moves in a direction from the first device end 144 to the second device end 146 of the film adhering device 132.

A heater is configured to heat the paint film 168. The vacuum device is configured to vacuums air out of the first and second housings 152 and 154 to thereby secure the heated paint film 168 to the component 180. In one example, the second housing 154 may be attached to a compressed air tank. Compressed air may be released from the compressed air tank into a second portion 186 of the vacuum sealed chamber 156 between the paint film 168 and the second housing 154 when the component stand 184 is in the second stand position and the component 180 is pressed into the paint film 168. Compressed air is used to further secure the paint film 168 onto the component 180.

The film positioning device 134 is a film revolver. The film positioning device 134 is positioned adjacent to the film adhering device 132. In the illustrated example, the film positioning device 134 is positioned adjacent to the first device side 148 of the film adhering device 132. The film positioning device 134 includes a device housing 190 and a device stand 192.

The device housing 190 may be rotatable by applying a rotational force to the device housing 190. The device housing 190 may be rotatable using a first actuator (e.g., first actuator 112), based on input from the control module. More specifically, the device housing 190 is rotatable about a core 194 of the device housing 190. The device housing 190 is rotatable in a clockwise direction in the example shown. In another example, the device housing 190 is rotatable in a counterclockwise direction. In yet another example, the device housing 190 is rotatable in a clockwise and a counterclockwise direction.

The device housing 190 is illustrated as having a circular side view shape. However, the device housing 190 may have another suitable side view shape, such as square or triangular. The device housing 190 includes a plurality of slots 198 disposed annularly about the core 194. Each of the plurality of slots 198 are annularly spaced apart from each other. Each of the plurality of slots 198 extend from an outer surface 200 of the device housing 190 in a radially inward direction. In the illustrated example, the plurality of slots 198 includes four slots. However, another suitable number of slots may be used.

Each of the plurality of slots 198 is shaped and sized to receive one of the plurality of paint film rolls 138. A roll holder 204 is disposed between each of the plurality of slots 198. The roll holder 204 is configured to removably hold the plurality of paint film rolls 138 to the device housing 190.

In one example, a robot (e.g., robot 326) is configured to load and unload the plurality of paint film rolls 138 into and out of the plurality of slots 198 of the device housing 190.

The film support wheel 136 is disposed between the film adhering device 132 and the film positioning device 134. In some configurations, the film support wheel 136 may be directedly attached to the film adhering device 132. In other configurations, the film support wheel 136 may be directly attached to the film positioning device 134.

The film support wheel 136 includes a wheel 206 and a wheel stand 208. The wheel 206 is rotatable and supports movement of the paint film 168, such as while the second clamp 164 moves from the first clamp position to the second clamp position. The wheel stand 208 holds the wheel 206 such that the wheel 206 is positioned adjacent to the first clamp 160 of the film adhering device 132.

FIG. 3 is a schematic of the paint film roll 138 positioned within the film positioning device 134. In the illustrated example, a first rod 220 extends through each of the plurality of paint film rolls 138.

The first rod 220 is removably secured to the roll holder 204 of the device housing 190. The roll holder 204 includes a pair of receivers 222 disposed at each of the plurality of slots 198. The pair of receivers 222 are at least partially aligned with opposing ends of the first rod 220.

The first rod 220 may be pressed into the pair of receivers 222 to secure the paint film roll 138 to the device housing 190 in a press-fit configuration. The first rod 220 may be pulled out of the pair of receivers 222 to release the paint film roll 138 from the device housing 190. In another example, each of the pair of receivers 222 is a clamp. The pair of clamp are movable to clamp the first rod 220 to the device housing 190 and release the first rod 220 from the device housing 190, based on input from the control module.

In some configurations, the paint film roll 138 may not include a first rod extending through the paint film roll 138.

FIG. 4 is a schematic of another example roll holder 230 of the example film positioning device 134.

The roll holder 230 includes a second rod 232 and a hinge 234. The second rod 232 is disposed within each of the plurality of slots 198 of the device housing 190. The second rod 232 is pivotally movable via the hinge 234 between a first rod position (shown in solid lines in FIG. 4) and a second rod position (shown in phantom lines in FIG. 4), based in input from the control module.

The hinge 234 is disposed within each of the plurality of slots 198 of the device housing 190. The hinge 234 is positioned at one end of the second rod 232 and attaches the second rod 232 to the device housing 190.

When the second rod 232 is in the first rod position, the second rod 232 is pivoted in a radially outward direction relative to the device housing 190. The second rod 232 may be positioned partially outside a respective slot of the plurality of slots 198. The second rod 232 is positioned to load the paint film roll 138 onto the device housing 190 or unload the paint film roll 138 from the device housing 190. More specifically, the robot may slide the paint film roll 138 onto and off of the second rod 232 to load and unload the paint film roll 138, respectively.

When the second rod 232 is transitioned from the first rod position to the second rod position, the second rod 232 is positioned within the respective slot 198 to secure the paint film roll 138 to the device housing 190.

FIG. 5 is a front view of another example roll holder 240 of the example film positioning device 134.

The roll holder 240 includes a pair of second rods 242 and a pair of hinges 244. A first one of the second rods 242 is positioned at a first side 246 of a respective slot 198. A second one of the second rods 242 is positioned at a second side 248 of the respective slot 198. The second side 248 is opposite to the first side 246. The first and second ones of the second rods 242 are spaced apart from each other. The first one of the second rods 242 pivotally moves using a first one of the pair of hinges 244. The second one of the second rods 242 pivotally moves using a second one of the pair of hinges 244.

The pair of second rods 242 are in a mirror image configuration with each other. The pair of the second rods 242 may move concurrently between a first rod position (shown in solid lines in FIG. 5) and a second rod position (shown in phantom lines in FIG. 5).

When the pair of second rods 242 are in the first rod position, the pair of second rods 242 are pivoted in a radially outward direction. The pair of second rods 242 may be partially positioned outside a respective slot of the plurality of slots 198. The pair of second rods 242 are positioned to load the paint film roll 138 onto the device housing 190 and unload the paint film roll 138 from the device housing 190. More specifically, the robot may insert and remove ends of the paint film roll 138 into and out of the pair of second rods 242 to load and unload the paint film roll 138, respectively.

When the pair of second rods 242 are transitioned from the first rod position to the second rod position, the pair of second rods 242 are at least partially received within the paint film roll 138 at opposing ends of the paint film roll 138 to secure the paint film roll 138 to the device housing 190. The pair of second rods 242 are aligned with each other. A spacing (distance) between adjacent ends of the pair of second rods 242 is less than a width of a paint film roll 138. Thus, the paint film rolls 138 are restricted from sliding off of the pair of second rods 242.

Another suitable design may be used to secure the paint film roll 138 to the film positioning device 134 and release the paint film roll 138 from the film positioning device 134.

FIG. 6 is a schematic of another example film positioning device 260.

The film positioning device 260 is a film conveyor. The film positioning device 260 includes a conveyor 262 and a stand 264. The conveyor 262 is rotatable. In one example, the conveyor 262 is rotatable in a clockwise direction. In another example, the conveyor 262 is rotatable in a counterclockwise direction. In yet another example, the conveyor 262 is rotatable in a clockwise and a counterclockwise direction.

The conveyor 262 extends between a first conveyor end 266 and a second conveyor end 268 that is opposite to the first conveyor end 266. A first wheel 270 is disposed at the first conveyor end 266 and a second wheel 272 is disposed at the second conveyor end 268. A support beam 274 extends between the first wheel 270 and the second wheel 272. The first wheel 270 and the second wheel 272 are rotatable.

A conveyor belt 280 is coupled to the first and second wheels 270, 272. More specifically, the conveyor belt 280 is in abutting contact with the first and second wheels 270, 272. In the illustrated example, the conveyor belt 280 includes chain. However, the conveyor belt 280 may include another suitable material.

A plurality of paint film rolls 282 is attached to the conveyor belt 280. In the illustrated example, six paint film rolls are attached to the conveyor belt 280. However, another suitable number of paint film rolls 282 may be attached to the conveyor belt 280.

Each of the plurality of paint film rolls 282 is removably attached to the conveyor belt 280 using a roll holder 284. The roll holder 284 may be positioned perpendicular to the conveyor belt 280. However, the roll holder 284 may be positioned in another suitable configuration relative to the conveyor belt 280.

The roll holder 284 extends between a first holder end 286 and a second holder end 288 that is opposite to the first holder end 286. The first holder end 286 is attached to the conveyor belt 280. The second holder end 288 is attached to one roll of the plurality of paint film rolls 282. The second holder end 288 of the roll holder 284 may have a U-shape, or another suitable shape.

Each of the plurality paint film roll 282 may be removably secured to the second holder end 288 of the roll holder 284, such as by a robot (e.g., robot 326 shown in FIGS. 7-9). In one example, and as described with reference to FIG. 3, each of the plurality of paint film rolls 282 may include a first rod (e.g., first rod 220) that extends through the respective paint film roll 282. The first rod may be removably attached to the roll holder 284 using a pair of receivers (e.g., pair of receivers 222).

In another example, and as described with reference to FIG. 4, the roll holder 284 may be the same as the roll holder 230. In yet another example, and as described with reference to FIG. 5, the roll holder 284 may be the same as the roll holder 240. Thus, the roll holder 284 will not be redescribed in detail.

Another suitable design may be used to secure the paint film roll 282 to the conveyor belt 280 and release the paint film roll 282 from the conveyor belt 280.

In one example, the conveyor belt 280 may be rotated around the support beam 274 by applying a rotational force to the conveyor belt 280. In another example, an actuator (e.g., first actuator 112), such as an electric motor, is configured to rotate the first and second wheels 270, 272, based on input from the control module. Rotation of the first and second wheels 270, 272 drives rotation of the conveyor belt 280 around the support beam 274. Rotation of the conveyor belt 280 thereby drives rotation of the plurality of paint film rolls 282 around the support beam 274.

FIG. 7 is a schematic of an example forming over part system 324 including an example robot 326. FIG. 8 is a schematic of the example robot 326 having an end effector 328. FIG. 9 is a schematic of the example robot 326, where the end effector 328 is grasping one of a plurality of paint film rolls 330.

The forming over part system 324 includes a film adhering device 332, a film positioning device 334, the robot 326, a paint film roll stand 338 and a control module (e.g., control module 106). The film adhering device 332 is the same as the film adhering device 132 of the forming over part system 130. The film positioning device 334 is the same as the film positioning device 134 of the forming over part system 130. Thus, the film adhering device 332 and the film positioning device 334 will not be redescribed in detail.

The robot 326 may have a suitable number of degrees of freedom (DOF), such as 6 DOF or higher. The robot 326 may include a base 344 and a robot arm 346. The robot arm 346 extends between a first arm end 348 and a second arm end 350 that is opposite to the first arm end 348. The first arm end 348 of the robot arm 346 is attached to the base 344. The second arm end 350 of the robot arm 346 is attached to the end effector 328.

The end effector 328 extends between a first end effector end 352 and a second end effector end 354 that is opposite to the first end effector end 352. The first end effector end 352 is attached to the second arm end 350 of the robot arm 346. The second end effector end 354 is configured as a clamp to grasp and release one of the plurality of paint film rolls 330, based on input from the control module. The end effector 328 extends between a first end effector side 356 and a second end effector side 358 that is opposite to the first end effector side 356.

The end effector 328 includes a top wall 362 and opposing sidewalls 364. The top wall 362 is disposed at the first end effector end 352 and extends between the first and second end effector sides 356, 358. A first one of the sidewalls 364 extends from the top wall 362 and is positioned at the first end effector side 356. The second one of the sidewalls 364 extends from the top wall 362 and is positioned at the second end effector side 358. Accordingly, the end effector 328 has a U-shape. However, the end effector 328 may have another suitable shape.

Each of the plurality of paint film rolls 330 may include a first rod 370 (e.g., first rod 220) that extends through the respective paint film roll 330. The second end effector end 354 end effector 328 of the robot 326 may grasp and release ends of the first rod 370, based on input from the control module.

In some configurations, the first rod 370 may not extend through each of the plurality of paint film rolls 330. As described with reference to FIG. 4, the end effector 328 may include a first roll holder that is the same as the roll holder 230. In another example, and as described with reference to FIG. 5, the end effector 328 may include a first roll holder that is the same as the roll holder 240. Thus, the first roll holder will not be redescribed in detail.

The paint film roll stand 338 includes a stand base 374 and a plurality of second roll holders 376. The plurality of second roll holders 376 extend from the stand base 374 and are spaced apart from each other along the stand base 374. In the illustrated example, the plurality of second roll holders 376 includes four roll holders. However, the plurality of second roll holders 376 may include another suitable number of second roll holders, such as six roll holders or eight roll holders.

Each of the plurality of second roll holder 376 is configured to hold one of the plurality of paint film rolls 330. In the illustrated example, a first one of the plurality of second roll holders 376 is holding a first one of the plurality of paint film rolls 330 that has a first color. A second one of the plurality of second roll holders 376 is holding a second one of the plurality of paint film rolls 330 that has a second color. A third one of the plurality of second roll holders 376 is holding a third one of the plurality of paint film rolls 330 that has a third color. The robot 326 is carrying a fourth one of the plurality of paint film rolls 330 from a fourth one of the plurality of second roll holders 376 to the film positioning device 334.

The robot 326 is configured to operate based on input from the control module. More specifically, the robot 326 is configured to change one of the paint film rolls 330 that are disposed within the film positioning device 334, based on input from the control module. Examples of input from the control module include a request for a predetermined color of a paint film roll 330 to be moved to a predetermined slot of the film positioning device 334, a notice when an amount (e.g., length) of a paint film of one of the paint film rolls 330 is below a predetermined threshold, and another suitable information.

The end effector 328 of the robot 326 is configured to grasp one of the paint film rolls 330 from the paint film roll stand 338, based on input from the control module of a selected color of the paint film roll 330. The robot 326 is configured to carry the one of the paint film roll 330 from the paint film roll stand 338 to the film positioning device 334, based on input from the control module of a selected route. The robot 326 is configured to release the paint film roll 330 into the film positioning device 334, based on input from the control module of a selected slot (e.g., slot 198) of the film positioning device 334.

The end effector 328 of the robot 326 is configured to grasp one of the paint film rolls 330 from one of the slots of the film positioning device 334, based on input from the control module of a selected slot of the film positioning device 334. The robot 326 is configured to carry the paint film roll 330 from the film positioning device 334 to the paint film roll stand 338, based on input from the control module of a selected route. The robot 326 is configured to release the paint film roll 330 onto the paint film roll stand 338, based on input from the control module of a selected second roll holder 376 of the paint film roll 330.

FIG. 10 is a schematic of an example forming over part system 424 including an example robot 426. The forming over part system 424 is the same as the forming over part system 324, with the exception of the film positioning device. A film positioning device 430 of the forming over part system 424 may be the same as the film positioning device 260, having a film conveyor style. Thus, the forming over part system 424 will not be re-described in detail.

FIG. 11 is a schematic of an example forming over part system 444 including an example robot 446. The forming over part system 444 is the same as the forming over part systems 324, 424, with the exception of the film positioning device. Thus, the forming over part system will not be re-described in detail.

The forming over part system 444 includes a film holding device 450. The film holding device 450 is configured to hold a single paint film roll 452. The film holding device 450 includes a device stand 456 and a roll holder 458. The roll holder 458 is disposed at a top stand end 460 of the device stand 456.

Each of the plurality of paint film rolls 452 may include a first rod (e.g., first rod 220, 370) that extends through the respective paint film roll 452. The robot 446 is configured to secure and release the paint film roll 452 from the roll holder 458 using the first rod. As described with reference to FIG. 3, the roll holder 458 may be the same as the roll holder 204 and will not be redescribed in detail.

In some configurations, the first rod may not extend through each of the plurality of paint film rolls 452. As described with reference to FIG. 4, the roll holder 458 may be the same as the roll holder 230. In another example, and as described with reference to FIG. 5, the roll holder 458 may be the same as the roll holder 240. Thus, the roll holder 458 will not be redescribed in detail.

FIG. 12 is a schematic of an example defect detection system 468 of a forming over part system 470.

The forming over part system 470 includes a film adhering device 472, a film positioning device 474, a film support wheel 476, and the defect detection system 468. The defect detection system 468 includes a camera 480 and a control module 482.

The film adhering device 472 is the same as the film adhering device 132 of the forming over part system 130. Thus, the film adhering device 472 will not be re-described in detail.

In one example, the film positioning device 474 is the same as the film positioning device 134. In another example, the film positioning device 474 is the same as the film positioning device 260. In yet another example, the film positioning device 474 is the same as the film holding device 450. Thus, the film positioning device 474 will not be re-described in detail.

The film support wheel 476 is disposed between the film positioning device 474 and the film adhering device 472. The film support wheel 476 is the same as the film support wheel 136 of the forming over part system 130 and thus will not be re-described in detail.

A blade 486 is disposed between the film support wheel 476 and the film positioning device 474. The blade 486 is pressed into a paint film 488 of a paint film roll and used to cut the paint film 488.

The camera 480 is disposed between the film support wheel 476 and the film positioning device 474. In one example, the camera 480 is an in-line scanning camera. The camera 480 is configured to, e.g., continuously capture images of the paint film 488 as the paint film 488 is passed by the camera 480. In one example, the camera 480 is configured to capture images having a height of one pixel and a width equal to a width of the paint film roll.

The control module 482 is configured to detect whether a defect in the paint film 488 exists based on the images captured by the camera 480. When a defect is detected, the blade 486 is used to cut a piece of the paint film 488 having the defect and the film adhering device 472 is configured to scrap the piece, based on input from the control module 482.

In one example, the control module 482 determines a depth of a top surface of the paint film 488 based on the images. More specifically, the control module 482 is configured to determine a first depth value in a first area of the paint film 488 and a second depth value in a second area of the paint film 488. The control module 482 is configured to determine whether a difference between the first and second depth values is greater than a predetermined value. If the difference between the first and second depth values is greater than a predetermined value, the control module 482 identifies the paint film 488 to have a defect.

In another example, the control module 482 determines a color value of the paint film 488 based on the images. For example, the control module 482 is configured to determine a first red green blue (RGB) value in a first area of the paint film 488 and a second RGB value in a second area of the paint film 488. The control module 482 is configured to determine whether a difference between the first and second RGB values is greater than a predetermined value. If the difference between the first and second RGB values is less than a predetermined value, the control module 482 identifies the paint film to have a defect.

In yet another example, the control module 482 determines a contrast value of the paint film 488 based on the images. For example, the control module 482 is configured to determine a first contrast value in a first area of the paint film 488 and a second contrast value in a second area of the paint film 488. The control module 482 is configured to determine whether a difference between the first and second contrast values is greater than a predetermined value. If the difference between the first and second contrast values is greater than a predetermined value, the control module