Coating thickness optimization for a robotized thermal spray system

Ren，Jiangzhuo1,2,3; Sun，Yiding3; Hui，Jizhuang1,2; Ahmad，Rafiq3; Ma，Yongsheng3,4

2023-10-01

10.1016/j.rcim.2023.102569

Robotics and Computer-Integrated Manufacturing   Impact Factor & Quartile

0736-5845

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.

Coating distribution optimization Robotized thermal spray process Thermal spray path Trajectory generation

English

Others

China Scholarship Council[201808180001];

ENGINEERING

2-s2.0-85151031549

Scopus

1.Key Laboratory of Road Construction Technology and Equipment of MOE,Chang'an University,Xi'an,710064,China
2.School of Construction Machinery,Chang'an University,Xi'an,710064,China
3.Department of Mechanical Engineering,University of Alberta,Edmonton,T6G 2E1,Canada
4.Department of Mechanical and Energy Engineering,Southern University of Science and Technology,Shenzhen,518055,China

Ren，Jiangzhuo,Sun，Yiding,Hui，Jizhuang,et al. Coating thickness optimization for a robotized thermal spray system[J]. Robotics and Computer-Integrated Manufacturing,2023,83.

Ren，Jiangzhuo,Sun，Yiding,Hui，Jizhuang,Ahmad，Rafiq,&Ma，Yongsheng.(2023).Coating thickness optimization for a robotized thermal spray system.Robotics and Computer-Integrated Manufacturing,83.

Ren，Jiangzhuo,et al."Coating thickness optimization for a robotized thermal spray system".Robotics and Computer-Integrated Manufacturing 83(2023).