System and method for autonomous application of a coating to a workpiece

A method comprising:

• accessing a target minimum coating thickness and a target maximum coating thickness for a coating applied to a workpiece;
• accessing a virtual model representing a surface contour of the workpiece;
• accessing a first depth value on the workpiece;
• based on the virtual model, defining a first set of coating parameters predicted to yield a first target coating thickness of the coating, applied to the workpiece, biased toward the target minimum coating thickness;
• applying the coating onto the workpiece based on the first set of coating parameters;
• accessing a second depth value on the workpiece;
• calculating a first applied coating thickness on the workpiece based on the first depth value and the second depth value;
• and
• in response to the first applied coating thickness falling below the target minimum coating thickness:
• defining a second set of coating parameters corresponding to a second target coating thickness less than a difference between the first applied coating thickness and the target maximum coating thickness;
• and
• applying the coating onto the workpiece according to the second set of coating parameters.

A system comprising:

• a robotic system:
• arranged proximal a work zone;
• and
• comprising:
• a spray coating applicator configured to spray a coating onto a workpiece;
• and
• a set of actuators configured to navigate the spray coating applicator within the work zone;
• a controller configured to:
• access a target minimum coating thickness and a target maximum coating thickness for the coating applied to the workpiece occupying the work zone;
• access a virtual model representing a surface contour of the workpiece;
• access a first depth value on the workpiece;
• and
• based on the virtual model, defining a first set of coating parameters predicted to yield a first target coating thickness of the coating, applied to the workpiece, biased toward the target minimum coating thickness;
• wherein the robotic system is configured to:
• drive the set of actuators to navigate the spray coating applicator across the workpiece;
• and
• trigger the spray coating applicator to apply the coating to the workpiece according to the first set of coating parameters;
• wherein the controller is configured to:
• access a second depth value on the workpiece;
• calculate a first applied coating thickness on the workpiece based on the first depth value and the second depth value;
• and
• in response to the first applied coating thickness falling below the target minimum coating thickness:
• define a second set of coating parameters corresponding to a second target coating thickness less than a difference between the first applied coating thickness and the target minimum coating thickness;
• and
• wherein the robotic system is configured to:
• drive the set of actuators to navigate the spray coating applicator across the workpiece;
• and
• trigger the spray coating applicator to apply the coating to the workpiece according to the second set of coating parameters.