喷涂机器人喷涂均匀性的规划

提出了一种针对喷涂均匀性的设计方案。介绍了喷涂机器人的喷头数学模型,并根据其数学模型确定了喷涂间距与喷枪到门距离的关系。对比了二次喷涂重叠与三次喷涂重叠的厚度差别,确立使用二次喷涂重叠。针对间距改变时的厚度变化情况,提出了一种后移喷枪使喷涂趋于均匀的轨迹规划方法。同时对喷涂过程中喷枪的参数作了分析与处理,使得物体表面较为简单的实现喷涂均匀。     

家具喷涂机器人喷枪轨迹生成分析与研究

根据喷漆机器人自动轨迹生成系统的组成与结构,提出了针对家具喷涂的喷漆机器人喷枪轨迹的设计方案.该方案以使家具表面漆膜厚度差达到最小为设计目标,在喷枪方向及空间路径为已知和未知两种条件下,分别给出了沿指定空间路径和基于自由表面的喷枪最优轨迹的求解方法,以解决喷漆机器人喷枪最优轨迹的规划问题.     

喷涂机器人矩形喷枪建模分析与迷彩图案全覆盖路径规划

针对喷涂机器人迷彩涂装作业过程中边缘混色、圆弧过渡和无法实现多色精细化喷涂的问题，设计了一种具有直角边界、可防过喷的矩形喷枪，建立其涂料沉积模型。喷枪性能实验结果表明，改进后的矩形喷枪涂层厚度均匀，满足数码迷彩喷涂工艺需求。其次，采用角点检测算法提取数码迷彩图案角点坐标，同时以角点坐标为基础，建立数码迷彩图案的平面栅格地图。然后，提出改进的生物激励神经网络（BINN）方法，引入融合数码迷彩喷涂工艺的机器人移动规则，将神经元活性传播方向限定为互相正交的4个方向，以缩小神经元动态激励场景范围，降低其计算复杂度。最后，采用基于矩阵变换的方法，将2维路径映射至车辆模型表面，生成3维迷彩喷涂路径。通过仿真与数码迷彩喷涂实验验证了所提方法的有效性，降低了生物激励神经网络的计算复杂度，解决了机器人喷涂过程中油漆过喷与数码迷彩喷涂路径难以规划的问题。     

针对规则化工件曲面的喷涂轨迹规划研究

基于大曲率复杂自由曲面可被分片造型成若干个近似平面、圆柱面、圆锥面和球面组合的思想,文中分别针对平面、圆柱面,圆锥面、球面等不同规则化曲面的喷涂轨迹优化进行研究。首先根据平面的静态喷涂模型分别建立圆柱面、圆锥面、球面的喷涂模型,并以涂层均匀性为优化目标求解优化的路径参数,喷枪速度v和喷涂间距d,在此基础上分别给出针对平面、圆柱面、圆锥面、球面的喷枪轨迹的生成算法。最后通过仿真验证了所提方法的有效性、正确性。     

发那科——紧凑型喷涂机器人Paint Mate 200iA

发那科近日推出智能紧凑型喷涂机器人新品——Paint Mate 200iA,该机器人基于公司广受欢迎的LR Mate 200iC机器人系列,用途定位于小部件的喷涂,同时允许安装多种型号的喷枪,具有极高的性价比。     

安全评估让机器人的效率更高

安全风险评估,让油漆喷枪机器人制造商成功开发出一套控制系统既不影响工作性能,还可以提供合适的安全保障。Dürr Paint Systems公司的创新精神让它成为了世界上首屈一指的油漆喷涂设备供应商。它那正被广泛用于多达2000个应用场合的Ecopaint机器人就是最好的例证。     

一种船体分段漆料全覆盖的喷涂路径规划方法

针对船体分段规则结构面喷涂不能够满足漆料全覆盖的现状,提出一种基于灰狼算法的船体分段结构面漆料全覆盖的喷涂路径规划方法。首先根据待喷涂结构面范围构建平面喷枪喷涂模型,确定区域全覆盖喷涂路径目标函数,通过灰狼算法求解目标函数获得喷涂间距、速度等关键参数进行仿真喷涂。结果表明,采用规划后的路径进行喷涂能够使漆膜覆盖且不超出整个结构面,同时保证了漆膜厚度平整性,从而有效提高了漆料利用率与喷涂效率,达到改善船体结构面喷涂的目标。     

日本白光优质制作工具

扁平IC拆焊台图1所示为白光850B扁平集成电路拆焊台,由控制台和喷枪两部分组成,控制台耗电30W、喷枪耗电270W,真空泵为膜片式、风量最高23升/分且可调节,喷枪热空气温度可在100～—420℃范围调节,并采用除静电设计,适于拆除各种尺寸的表面贴装扁平IC、使用安     

玩具喷漆机器人控制系统研究

为实现玩具表面线条的自动喷漆,设计了基于运动控制卡、触摸屏软件的八轴玩具喷漆机器人系统。系统由送料、喷涂、清洗三部分组成。该系统利用运动控制卡的多轴控制通过触摸屏设计轨迹的方法实现对玩具表面线条进行喷涂,以运动控制卡为核心实现玩具表面线条喷涂的整体控制。实验表明:该控制系统完全能够满足玩具喷漆复杂的工艺要求可以实现复杂的喷涂路径比如圆弧、立体、单次立体等,喷涂效果完全符合玩具喷漆工艺的要求。     

一种结合机器视觉的工件喷涂质量检测方法

针对大型多面复杂结构件表面打磨、喷涂等处理对自动化、智能化的需求,传统目标检测具有局限性、小目标检测准确度低、速率慢等缺点,本文结合计算机视觉提出一种改进YOLOv3算法的工件喷涂质量检测方法,结合实际工控环境需求,构建喷涂数据集,实现对工件表面迷彩喷涂质量的检测.首先,使用K-means++对Anchor重新聚类生成...     

Coating thickness optimization for a robotized thermal spray system

Thermal spraying techniques are used to protect or improve the surface performance of a workpiece by adding melted (or heated) powders onto the surface. Thickness and uniformity control are critical for obtaining an excellent thermal spraying coating. In the contemporary manufacturing industry, with the increasing demand for efficient and accurate processes, robot manipulators and handling systems have been developed to control the movement of the spray gun relative to the workpiece surface, where the robot manipulators and handling systems lead the spray gun to reciprocate along a predefined path. However, the research on optimizing the path for generating the desired coating thickness is very limited. In this paper, a parametric coating thickness prediction model is adapted from our previous research. Then, the Nelder-Mead method drives the model to find out the optimal kinematic parameters of a zigzag (meander) path for a uniform coating with the desired thickness. Based on the obtained kinematic parameters, the trajectory and program of a robot end effector (spray gun) are yielded. Finally, a prototype system with an intuitive user interface is developed to integrate these functions. From the input of a Gaussian coating growth model and a substrate, it can provide an optimal path directly. At the end of this work, one case was implemented by a homemade spray system and a robot system for verifying the effectiveness of the system.     

Process modeling,simulation, and paint thickness measurement for robotic spray painting

An algorithm and a computer program are developed for modeling of the spray painting process, simulation of robotic spray painting, and off‐line programming of industrial robots for painting of curved surfaces. The computer program enables the user to determine the painting strategies, parameters, and paths which will give the desired paint thickness. Surface models of the parts that are to be painted are obtained by using a computer‐assisted design (CAS) software. Models of relatively simple surfaces are formed by using the surface generation tools of the CAD software. For parts with more complex surfaces, point data related to the part is collected by using a laser scanner, and this data is used to form the CAD model of the part surface. The surface is then divided into small triangular elements and centroid coordinates, and unit normals of the elements are determined. Surface data together with the spray distance, painting velocity, and paint flow rate flux are used for simulation of the process and paint thickness analysis. Paint flow rate flux is determined experimentally by using different spray gun settings and painting parameters. During the experiments flat surfaces are painted by using a single painting stroke of the gun. Then, paint thickness measurements are made on the surfaces. It is observed that besides the technical specifications of the spray gun, air and paint nozzles, and paint needle, basic settings like paint tank pressure, spray air pressure, and gun needle‐valve position affect paint cone angle and paint flow rate, which finally characterize the spray painting process. For that reason, settings and parameters should be changed and the painting process should be simulated until an acceptable paint thickness distribution is obtained for the part that is going to be painted. The robot program is then generated in the robot's programming language. Paint thickness distribution on the painted surface is determined by measuring the thicknesses using the robot and the CAD model of the part surface. The thicknesses are measured at the centroids of the surface elements. A measurement probe of the coating thickness measurement gauge is attached to the wrist of the robot by using a feedback/safety adapter designed and manufactured for this purpose. © 2000 John Wiley & Sons, Inc.     

基于全自动热喷涂技术的电力设备零部件涂层制备工艺研究

变电设施常常服役于空气环境中,容易受到腐蚀的影响,对设备进行表面改性处理可以大幅改善设施的防腐蚀性能,提升其使用寿命。全自动热喷涂技术作为一种新型表面改性方式,是通过热源将合金加热至熔融或半熔融状态并涂覆与基体表面的技术。本文对其工艺参数进行了系统研究,发现当喷涂速度为0.1m/s,涂层厚度最大(700μm)、孔隙最小(2.1%)、性能最佳。喷涂距离对涂层孔隙率的影响较大,在距离为180mm,孔隙率达到最低(4.3%),此外还可根据对涂层厚度需求以及孔隙率的大小选择合适的喷涂电压和电流。对最佳参数条件下热喷涂铝涂层的试样进行盐雾试验。发现涂层表面会发生氧化腐蚀,生成以Al(OH)₃为主的腐蚀产物并在涂层表面形成致密的氧化膜。此外,产生的腐蚀产物还可以填补热喷涂过程中形成的孔隙,阻止腐蚀介质继续向涂层内部渗入。     

Musculoskeletal exposure of manual spray painting in the woodworking industry – an ergonomic study on painters

In the present study the ergonomic conditions of manual spray painting in the woodworking industry have been studied. Manual spray painting is, despite rationalisations, quite common in the Swedish woodworking industry. Interviews with spray painters showed that they had higher prevalence of musculoskeletal symptoms in their right shoulder compared with other workers with manual work. A majority of the spray painters painted work-pieces lying on a work-table. A majority of these painters abduct the right upper-arm so much when painting the horizontal surface of the work-piece that they risk supraspinatus tendinitis. The upper-arm abduction when painting horizontal surfaces could be decreased without introducing new ergonomic disadvantages by installing work-tables with powered height control or possibly also by changing the geometry of the spray gun. Gripping the spray gun trigger was for some of the painters identified as causing a high risk for WMSD in the wrist. Lower spray gun trigger force would improve the situation. This could be done by the users in several ways, such as greasing the trigger mechanism and/or decreasing the spring pressure on the fluid needle.

Relevance to industry

The study highlights some major ergonomic problems for a fairly large group of workers in the woodworking industry.     

An ergonomic comparison of industrial spray paint guns

Two spray guns were used by 10 subjects in a laboratory. One gun was a `traditional' spray gun. The other was the OMX gun which had `ergonomic' features including reduced gun and hose weight and two triggers (one for horizontal surfaces and one for vertical). The 10 subjects (5 experienced industrial spray painters and 5 inexperienced students) used each gun for 4 h. The criteria used to evaluate the two guns were: (1) Wrist deviation in all three axes, (2) EMG frequency shift of 3 shoulder muscles over the test period, (3) integrated EMG activity of the forearm flexors, and (4) body discomfort ratings.It was found that the OMX gun resulted in significantly less radial/ulnar deviation in the wrist, and moderately increased flexion/extension and pronation/supination deviations from neutral. During the painting period, up to 50% less fatigue in the shoulder muscles was found for the OMX gun. Additionally, the triggering activation levels for sustained grip contractions were found to be acceptable for the OMX gun when using the short trigger. Finally, the amount of discomfort reported by the subjects was statistically lower in the shoulder, upper back, arm, elbow, forearm, wrist, and hand with the OMX gun design. Collectively, these results indicate that the OMX gun would be expected to reduce exposure to occupational risk factors for workers. This study demonstrated how the incorporation of ergonomic design principles can be used to minimize occupationally-related risk.Relevance to industryCumulative trauma disorders (CTDs) are soft tissue disorders resulting from repeated exertions and excessive movements of the body. Industrial spray painting fits the profile of a highly repetitive task. Improving spray paint gun design could potentially reduce the risk of CTDs in industrial spray painting tasks.     

Parameter optimization for spray coating

The aim of planning path-oriented spray-coating processes is to find a time-dependent continuous sequence of spray gun configurations so that a coating of desired thickness is achieved when executing the sequence. A novel approach to solving the planning task, called “geometry-last”, is outlined which leads to a more general gun configuration cover problem. The gun configuration cover problem is to find a finite set of spray gun configurations, which minimizes the error between a target coating and the coating induced by simultaneously activating those configurations. A suitable objective function for gun configuration covers is defined, and algorithmic solutions for the optimization problem are presented, including speed-up by hierarchization and use of graphics hardware. An experimental evaluation shows that good approximations of the desired coatings can be achieved within reasonable computing times. In contrast to other approaches, geometry-last gains additional flexibility required to find complex paths for free-form workpieces.     

煤与矸石在线分选系统设计

针对目前常用的原煤洗选方法存在设备复杂、需要大量的水等问题,设计了一种基于双能γ射线和数字图像识别技术的煤与矸石在线分选系统。单片机实时判断探测器下方的物料是煤或者是矸石,当判断为煤块时,喷枪无动作,煤块落入煤通道;当判断为矸石时,单片机控制喷枪喷出高压气体,将矸石吹入矸石通道;当有些煤中含杂质较多或者矸石含碳量较高时,则由图像识别模块根据煤与矸石在灰度上的差异来区分煤与矸石,并将识别结果传送给单片机。模拟实验结果表明,该系统能有效识别煤与矸石,识别精度满足工业生产要求。     

基于CAD模型的鞋底喷胶轨迹生成方法

针对数字化制鞋生产的需要,提出一种自动生成鞋底喷胶轨迹的方法．该方法首先从三维鞋楦CAD模型中提取鞋底轮廓线,计算其在鞋底曲面的偏置曲线作为轨迹曲线,采用等参数方法对轨迹曲线进行采样得到机器人喷胶轨迹上的目标点并计算出其方向．最后通过机器人喷胶试验验证了该方法的可行性和有效性．     

掘进机外喷雾降尘效率的研究与分析

为了提高掘进工作面的降尘效率,通过对喷雾降尘机理的研究,分析了影响降尘效率的因素,建立了纵轴式掘进机外喷雾降尘效率的数学模型,应用MATLAB软件绘制出降尘效率曲线。由此得出,雾化角度越小降尘效率越高,考虑到喷雾的均匀性和喷雾系统的稳定性,雾化角度50°左右为宜;随着喷雾压力的增大,降尘效率显著提高,当供水压力为10Mpa时,降尘效率能达到90%以上;喷嘴到尘源的距离越小,降尘效率越高,但是如果距离太近,喷雾作用范围小,降尘不充分,到尘源的距离为1.3~1.4m比较理想;喷嘴直径越大,降尘效率越高,在耗水量允许情况下,喷嘴直径由0.8mm增大到1.5mm,降尘效率由63%提高到89%。该项研究对于合理设计掘进机外喷雾参数,提高喷雾降尘性能,改善掘进工作面环境等具有一定的指导作用和参考价值。该项研究对于合理设计掘进机外喷雾参数,提高喷雾降尘性能,改善掘进工作面环境等具有一定的指导作用和参考价值。