Automatic Spray Painting

Abstract: With the advances in IT technology sensors and processing power exist to achieve fully automated robot programming in industrial tasks. This reports on the EU-project FlexPaint, which devised a methodology to automatically generate robot programs for spray painting of unknown parts. The solution uses four steps: laser triangulation sensing, geometric feature detection, tool path planning, and the generation of the collision-free executable robot program. Demonstrations at industrial partners show the results.

Keyword: Automated robot programming, feature detection, path generation, collision avoidance, spray painting.

1. INTRODUCTION

The objective of the European RTD project FlexPaint (www.flexpaint.org) is to automate robot programming for painting applications of small lot sizes with a very high number of part variants. Presently robotic painting is economically feasible for large lot sizes, since a robot program needs to be established (using off-line programming and/or manual teach-in) for each single part variant.

The project goal is to provide economic possibilities for usage of robots in painting of large part families (e.g., see Figure 1). The goal is to reduce human programming

effort by 75 percent and the human spray painting effort by 90

. .

2.BLOCK DIAGRAM (GENERAL OVERVIWE)



GENERAL SPRAY PAINTING:

Spray painting is a painting technique where a device sprays coating (paint, ink, varnish, etc.) through the air onto a surface. The most common types employ compressed gas usually air to atomize and direct the paint particles. Spray guns evolved from airbrushes, and the two are usually distinguished by their size and the size of the spray pattern they produce.

Airbrushes are hand-held and used instead of a brush for detailed work such as photo retouching, painting nails or fine art. Air gun spraying uses equipment that is generally larger.

It is typically used for covering large surfaces with an even coating of liquid. Spray guns can be either automated or hand-held and have interchangeable heads to allow for different spray patterns. Single color aerosol paint cans are portable and easy to store.

3. COMPONENTS OF SPRAY PAINTING:

The following are the components used to build up spray painting.

MICROLogix 1000:

MicroLogix 1000 controller brings high-speed, taking 1.5 ms for 500 program instructions, powerful instructions and flexible communication to applications.

The MicroLogix 1000 controller is available in 10-point, 16-point, or 32-point digital I/O versions. Analog versions are also available with 20 digital I/O points (12 inputs and 8 outputs), with 4 analog inputs (2 voltage and 2 current) and 1 analog output.

The MicroLogix 1000 Provide a compact form factor, With footprint as small as 120mm * 80mm * 40mm. 1 KB program and data memory for ease of operation Includes built-in EEPROM memory, no need for battery backup.

^{DC MOTOR:}
<sub>A DC motor is a mechanically commutated electric motor powered from direct current (DC). The stator is stationary in space by definition and therefore the current in the rotor is switched by the commutator to also be stationary in space. This is how the relative angle between the stator and rotor magnetic flux is maintained near 90 degrees, which generates the maximum torque.

The speed of a DC motor can be controlled by changing the voltage applied to the armature or by changing the field current. The introduction of variable resistance in the armature circuit or field circuit allowed speed control. Modern DC motors are often controlled by power electronics systems called DC drives.</sub>

INDUCTIVE PROXIMITY SENSOR:
An inductive sensor is an electronic proximity sensor, which detects metallic objects without touching them.
The sensor consists of an induction loop. Electric current generates a magnetic field, which collapses generating a current that falls asymptotically toward zero from its initial level when the input electricity ceases. The inductance of the loop changes according to the material inside it and since metals are much more effective inductors than other materials the presence of metal increases the current flowing through the loop. This change can be detected by sensing circuitry, which can signal to some other device whenever metal is detected. .
Common applications of inductive sensors include metal detectors, traffic lights, car washes, and a host of automated industrial processes. Because the sensor does not require physical contact it is particularly useful for applications where access presents challenges or where dirt is prevalent.
RELAY:
A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal. The first relays were used in long distance telegraph circuits as amplifiers: they repeated the signal coming in from one circuit and re-transmitted it on another circuit. Relays were used extensively in telephone exchanges and early computers to perform logical operations.

SUBMERSIBLE PUMP:
The submersible pumps used in ESP installations are multistage centrifugal pumps operating in a vertical position. Although their constructional and operational features underwent a continuous evolution over the years, their basic operational principle remained the same. Produced liquids, after being subjected to great centrifugal forces caused by the high rotational speed of the impeller, lose their kinetic energy in the diffuser where a conversion of kinetic to pressure energy takes place. This is the main operational mechanism of radial and mixed flow pumps.
The pump shaft is connected to the gas separator or the protector by a mechanical coupling at the bottom of the pump. Well fluids enter the pump through an intake screen and are lifted by the pump stages.Other parts include the radial bearings (bushings) distributed along the length of the shaft providing radial support to the pump shaft turning at high rotational speeds. An optional thrust bearing takes up part of the axial forces arising in the pump but most of those forces are absorbed by the protector’s thrust bearing.

4 ADVANTAGES:

1. It is economical

2. Less manpower required

3. Less time required

4. Avoids waste of colour
5. APPLICATION:

1.Auto-body shops

2.Sign painting shops

3.Furniture, door and appliance manufacturing facilities

4.Metal fabrication shops where oilfield equipment, heavy machinery and transportation equipment is manufactured and repaired

5.Sandblasting/coating facilities

6. LITERATURE REVIEW:
In this Report an inverse approach is presented to automatically obtain robotic paint paths from range sensor data and to automatically generate a feasible, complete and executable robot program.

The approach must cope with a large spectrum of parts as depicted. For each industrial customer the part families are known. The goal is to be able to paint any order of parts coming along the conveyor.

7. CONCLUSION:
An approach to automatically spray paint families of unknown parts has been presented. The approach uses a sensing cell in front of the painting cell, where the part geometry is acquired. From the part geometry process-relevant features are extracted and corresponding paint routines are found and grouped to obtain optimal painting trajectories. Finally a collision-free robot path and an executable robot program are generated.

All steps are fully automatic and no intervention of an operator is needed. The individual tool(FeatureFinder, PathPlanner, Tool Planner) exist in prototype versions. First implementations at industrial users show that the approach is feasible. Parts can be scanned and robot programs are generated automatically for a part rate of one per minute using conventional PC technology.

REFERENCES
BOOKS
Programmable Logic Controllers, Principle and Application(5th Addition,1994), By John W. Webb and Ronald A. Reis, Pub: Prentice - Hall India
Programmable Logic Controllers: Programming methods and applications(2003), by.John. R.Hackworth and Fredrick D. Hackworth Jr., Pub: Pearson

URL
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