Analysis of Coating Uniformity in Boundary Zone of Surface Spraying with Large-size
-
摘要: 针对喷涂机器人利用空气喷枪在大尺寸表面自动喷涂时面片交界区的涂层厚度均匀性难以保证问题,首先分析了导致涂层厚度偏差的原因,然后通过对平板匀速直行实验数据进行拟合,建立了一个具有喷涂起始、终止位置处涂层厚度分布描述的喷枪模型。在此模型基础上,对面片交界区的横向搭接参数进行了分析与数学最优值区间求解,得到了最优取值区间为0.2 ~ 0.4的结论。最终通过多组对比试验证明此参数准确,能够有效改善面片交界区的涂层厚度均匀性。Abstract: In response to the difficulty in ensuring uniformity of coating thickness in the boundary area of face sheets when the sparying robot automatically coats a large surface with an air spraying gun, the causes of coating thickness deviation were firstly analyzed, and then a spraying gun model with the description of coating thickness distribution at the start and end positions of spraying was established by fitting the experimental data of the flat plate at a uniform straight line. On the basis of the present model, the transverse lap parameters of the boundary area of the face sheet were analyzed and optimal value interval solving,and the optimal value interval is 0.2 - 0.4 was obtained. Finally, the present processing parameter is proved to be accurate and can effectively improve the coating thickness uniformity in the boundary area of the face sheet through multiple comparison tests.
-
表 1 喷涂参数
参数 数值 喷炬长轴长度/mm 300 喷炬短轴长度/mm 200 喷涂速度/(mm·s−1) 400 喷涂距离/mm 200 控制最大厚度/μm 12 表 2 厚度分布函数标定参数
标定参数 数值 函数参数 数值 D1 40 a1 −1.338 D2 12.5 b2 14.633 D3 25 a2 −1.138 x1 10 b2 112.274 x2 46 c −2743.323 x3 54 表 3 横向搭接率-标准差数据
项目 横向搭接率 0 1/3 1/2 2/3 1 标准差 6.84 4.51 5.01 9.63 10.9 -
[1] BALKAN T, ARIKAN M A S. Surface and process modeling and off-line programming for robotic spray painting of curved surfaces[C]//ASME 1999 Design Engineering Technical Conferences. Las Vegas: American Society of Mechanical Engineer, 1999: 455-466 [2] BALKAN T, SAHIR ARIKAN M A. Modeling of paint flow rate flux for circular paint sprays by using experimental paint thickness distribution[J]. Mechanics Research Communications, 1999, 26(5): 609-617 doi: 10.1016/S0093-6413(99)00069-5 [3] 刘雪梅, 刘涛, 杨连生, 等. 平面喷涂漆膜厚度分布规律研究与搭接参数优化[J]. 表面技术, 2018, 47(9): 116-125LIU X M, LIU T, YANG L S, et al. Spray painting film thickness distribution on panel and optimization of width of paint film overlay[J]. Surface Technology, 2018, 47(9): 116-125 (in Chinese) [4] 张永贵, 黄玉美, 高峰, 等. 喷漆机器人空气喷枪的新模型[J]. 机械工程学报, 2006, 42(11): 226-233 doi: 10.3321/j.issn:0577-6686.2006.11.037ZHANG Y G, HUANG Y M, GAO F, et al. New model for air spray gun of robotic spray-painting[J]. Chinese Journal of Mechanical Engineering, 2006, 42(11): 226-233 (in Chinese) doi: 10.3321/j.issn:0577-6686.2006.11.037 [5] 王国磊, 伊强, 缪东晶, 等. 面向机器人喷涂的多变量涂层厚度分布模型[J]. 清华大学学报(自然科学版), 2017, 57(3): 324-330WANG G L, YI Q, MIAO D J, et al. Multivariable coating thickness distribution model for robotic spray painting[J]. Journal of Tsinghua University (Science & Technology), 2017, 57(3): 324-330 (in Chinese) [6] 华霄桐, 张思敏, 刘兴杰等. 基于椭圆双β喷枪模型的喷涂轨迹优化[J]. 清华大学学报(自然科学版), 2020, 60(12): 985-992HUA X T, ZHANG S M, LIU X J, et al. Optimization of spraying trajectory based on elliptical double β spraying gun model[J]. Journal of Tsinghua University (Science & Technology), 2020, 60(12): 985-992 (in Chinese) [7] 缪东晶, 王国磊, 吴聊, 等. 自由曲面均匀喷涂的机器人轨迹规划方法[J]. 清华大学学报(自然科学版), 2013, 53(10): 1418-1423MIAO D J, WANG G L, WU L, et al. Trajectory planning for freeform surface uniform spraying[J]. Journal of Tsinghua University (Science & Technology), 2013, 53(10): 1418-1423 (in Chinese) [8] 曾勇. 大型复杂自由曲面的喷涂机器人喷枪轨迹优化研究[D]. 兰州: 兰州理工大学, 2011ZENG Y. The research on the spray tool trajectory optimization of painting robot for large and complex free-form curved surface[D]. Lanzhou: Lanzhou University of Technology, 2011 (in Chinese) [9] 陈伟. 喷涂机器人轨迹优化关键技术研究[D]. 镇江: 江苏大学, 2013CHEN W. Research on key techniques of robotic spray painting trajectory optimization[D]. Zhenjiang: Jiangsu University, 2013 (in Chinese) [10] 冯川, 孙增圻. 机器人喷涂过程中的喷炬建模及仿真研究[J]. 机器人, 2003, 25(4): 353-358 doi: 10.3321/j.issn:1002-0446.2003.04.015FENG C, SUN Z Q. Models of spray gun and simulation in robotics spray painting[J]. Robot, 2003, 25(4): 353-358 (in Chinese) doi: 10.3321/j.issn:1002-0446.2003.04.015 [11] 安静, 华霄桐, 孙新, 等. 基于互补喷枪模型的平面喷涂方法[J]. 组合机床与自动化加工技术, 2020(10): 155-158AN J, HUA X T, SUN X, et al. Planar spraying method based on complementary spray gun model[J]. Modular Machine Tool & Automatic Manufacturing Technique, 2020(10): 155-158 (in Chinese) [12] 冯浩, 吴秋, 王小平. 基于椭圆双β模型的球面喷涂轨迹优化[J]. 机械设计与制造, 2016(4): 249-252+257 doi: 10.3969/j.issn.1001-3997.2016.04.065FENG H, WU Q, WANG X P. Optimization of spraying trajectory for spherical surface based on ellipse dual-β model[J]. Machinery Design & Manufacture, 2016(4): 249-252+257 (in Chinese) doi: 10.3969/j.issn.1001-3997.2016.04.065 [13] FREUND E, ROKOSSA D, ROSSMANN J. Process-oriented approach to an efficient off-line programming of industrial robots[C]//Proceedings of the 24th Annual Conference of the IEEE Industrial Electronics Society. Aachen, Germany: IEEEE, 1998: 208-213. [14] SHENG W H, XI N, CHEN H P, et al. Part geometric understanding for tool path planning in additive manufacturing[C]//Proceedings of 2003 IEEE International Symposium on Computational Intelligence in Robotics and Automation. Computational Intelligence in Robotics and Automation for the New Millennium. Kobe: IEEE, 2003 [15] CONNER D C, GREENFIELD A, ATKAR P N, et al. Paint deposition modeling for trajectory planning on automotive surfaces[J]. IEEE Transactions on Automation Science and Engineering, 2005, 2(4): 381-392 doi: 10.1109/TASE.2005.851631 [16] 王海. 浅谈喷涂仿真在涂装同步工程分析中的导入及应用[J]. 现代涂料与涂装, 2020, 23(12): 52-54+66 doi: 10.3969/j.issn.1007-9548.2020.12.017WANG H. Introduction and application of spray simulation in painting synchronization engineering[J]. Modern Paint & Finishing, 2020, 23(12): 52-54+66 (in Chinese) doi: 10.3969/j.issn.1007-9548.2020.12.017 [17] 张丽梅. 机器人施釉轨迹优化仿真技术研究[D]. 唐山: 华北理工大学, 2020ZHANG L M. Trajectory optimization and simulation research based on robot glazing[D]. Tangshan: North China University of Science and Technology, 2020 (in Chinese)