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With the continuous development and improvement of modern spraying technology, the reform of spraying machine technology is also constantly underway. Nowadays, the requirements for automated industrial production are gradually increasing, and the principles of safety production and environmental protection are constantly being implemented.
The emergence of paint paint spraying robots has become inevitable, and this high-tech spraying equipment can also meet the requirements of various work pieces. What are the advantages of automatic paint spraying robots compared to traditional processes?
The paint spraying robot is composed of explosion-proof robot arms, which can safely spray coatings that may produce flammable gases. The robot also has an independent paint spraying system, which can control all aspects of spray parameters, such as atomization, voltage and paint flow.
Simultaneously paint spraying robots can improve coating quality, consistency, and output value, while reducing operating costs and minimizing material waste during the spraying process. Modern industrial robots use different plans to complete specific roles and automatically perform the tedious and harmful tasks involved in painting.
(1) Large activity radius and good flexibility.
(2) Can complete the spraying of inner and surface surfaces.
(3) Can complete mixed production of various vehicle models, such as sedans, station wagons, pickup trucks, and other body mixed production.
(1) Copy the spraying trajectory to improve the uniformity of the coating and other appearance spraying quality.
(2) Reduce the amount of spray coating and cleaning solvent used to improve data utilization efficiency.
(3) Uniform painting: Industrial robots can evenly paint parts and equipment with an appropriate amount of paint, without leaving dripping or other defects.
(1) Offline programming greatly reduces on-site debugging time.
(2) Plug in structure and modular design enable quick installation and replacement of components, greatly reducing maintenance time.
(3) All components have good accessibility for protection and easy maintenance.
The utilization rate of reciprocating active spraying machines is generally only 40% -60%, while the utilization rate of paint paint spraying robots can reach 90% -95%.
By using collision avoidance software, industrial robots can closely approach and operate in limited spaces without colliding with each other or requiring repairs.
The planning and programming of industrial robots can recognize the edges of equipment, so compared to manual labor, they can spray uniform paint without damaging the paint.
Small industrial robots have slender robotic arms that can be installed on shelves, rails, or walls, making them suitable for limited factory space.
paint spraying robots generally use servo motors with harmonic reducers, which have small size, large working range, fast speed, high precision, and can be integrated with auxiliary equipment such as turntables and slide conveyor chains for operation.
The whole machine is fully sealed, dustproof and waterproof, suitable for harsh environments such as automotive spraying and dust industry. Robots are changing our way of life, and painting is not outdated. Now industrial robots have come to us to improve painting quality and reduce paint waste.
paint spraying robots can achieve efficient and pollution-free spraying operations, making them an ideal equipment for modern industrial painting today. It can achieve automatic painting operations, improve painting quality and efficiency, completely replace manual painting, reduce painting costs, minimize pollution, reduce waste, and greatly improve production efficiency.
How to make the robot spray evenly, without bubbles, and save paint? The key lies in the parameter settings of the paint paint spraying robot.
Coating efficiency refers to the efficiency of spraying operations, including the spraying area per unit time, the effective utilization rate of paint and spraying area. Coating efficiency refers to the ratio of the amount of coating applied to the object to the actual total amount of coating sprayed during the spraying process, or the ratio of the measured thick film on the surface of the object to the coating thickness calculated from the amount of coating sprayed, which is the transmission efficiency or coating utilization rate of the coating.
Coating effectiveness refers to the ratio of the actual surface area of the sprayed object to the coverage area of the spray gun during operation. In order to ensure the integrity of the coating on the edge of the object being coated, the coverage area of the spray gun should generally be larger than the area of the object being coated.
The spraying trajectory of a paint spraying robot refers to the sequence and stroke of the spray gun during the spraying process. Using a paint spraying robot can mimic the spraying trajectory of a skilled painter.
The paint flow rate of a paint spraying robot is the amount of paint delivered to each rotary cup per unit time, also known as the spraying flow rate or paint output rate.
In addition to the rotational speed of the rotary cup, the coating flow rate is the second factor that affects the fineness of atomized particles. When other parameters remain constant, the lower the coating flow rate, the finer the atomized particles, but at the same time, it can also lead to an increase in solvent evaporation in the paint mist.
A high flow rate of paint in the paint spraying robot will form a wavy coating. At the same time, when the paint flow rate is too high and the rotary cup is overloaded, the coating on the edge of the rotary cup thickens to a certain extent, causing the grooves and patterns on the rotary cup to prevent the paint from flowing and resulting in layered paint, which can cause adverse phenomena such as bubbles or uneven droplet sizes.
The maximum coating flow rate of each spray gun of the paint spraying robot is related to the diameter of the high-speed rotary cup and the density of the coating at different speeds. Its upper limit is determined by the fineness of atomization and the effect of electrostatic coating. Practical experience has shown that coatings should be input at a constant speed, and fluctuations within a small range will not affect the quality of the coating film.
In the actual spraying process, the paint spraying robot sprays different areas on each rotary cup, and the flow rate of the coating is also different. In addition, due to changes in the shape of the object being coated, the flow rate of the coating on the rotary cup also changes.
Taking the spraying of car bodies as an example, when spraying large areas such as door panels, the amount of paint sprayed should be large, while when spraying door pillars and window pillars, the amount of paint sprayed should be small.
Only by automatically and accurately controlling the amount of paint sprayed during the spraying process can the quality and thickness of the coating be ensured, which is also one of the important measures to improve the utilization rate of the coating.
The rotational speed of the spray robot's rotary cup is the most significant factor affecting the atomization fineness of high-speed rotary cups. When other process parameters remain constant, the larger the rotational speed of the rotary cup, the smaller the diameter of the coating droplets. In the slightly low-speed range, the influence of rotational speed on atomization fineness is significantly greater than in the high-speed range.
The rotational speed of the spray robot's rotary cup will have an impact on the film thickness. When the speed is too low, it will cause the coating to become rough.
paint spraying robots that atomize too finely can cause paint mist loss (resulting in overspray), causing fluctuations in coating thickness. Meanwhile, when atomized ultrafine, it is highly sensitive to any airflow inside the paint booth. The excessive speed of the rotary cup not only causes overspray, but also leads to excessive wear of the turbine bearings, increases the consumption of compressed air for cleaning, and reduces the solvent content in the coating.
The optimal rotation speed of the spray robot can be determined by the flow rate characteristics of the coating used, so the rotation speed for water-based coatings with surface tension and high viscosity two-component coatings is higher than that for ordinary solvent based coatings.
In general, the idle rotating cup speed of the paint spraying robot is 6X10 ^ 4r/min, and the set speed range under load is (1.0-4.2) X10 ^ 4r/min with an error of ± 500r/min.
Electrostatic spraying technology has become the mainstream spraying technology in today's automotive industry, and the application of electrostatic automatic spraying equipment has brought the automotive middle and surface coating into the era of automation. Below is a brief description of the main spraying parameters of the paint spraying robot.
The flow rate of an electrostatic paint spraying robot is the amount of paint delivered to the rotary cup per unit time, also known as the discharge volume. The size of the flow rate affects the thickness of the paint film.
Different colors of coatings have different covering abilities and construction film thicknesses. During the spraying process, each robot is responsible for different spraying areas and sets different flow rates.
At the same time, the flow rate is also related to the shape of the sprayed material. For cars, the regular five door one cover shape generally has a larger flow rate, while the column, edge line, and corner flow rate are smaller.
Gas is sprayed out from the small holes evenly distributed on the back of the rotary cup, which is used to limit the amplitude of the paint mist (fan width) and push the atomized paint mist towards the object to be coated, allowing the paint mist to diffuse and rebound, contaminating the rotary cup and atomizer.
For metallic paint, the spray width affects the final color effect, and an inappropriate spray width can easily lead to zebra stripes or blurred hair. The setting of the spray width is related to the spacing between the two guns, and the number of times the paint is stacked is 3 times. If the distance between two guns is 100mm, it is best to control the spraying width to 300mm, so that the same point of paint can be stacked three times.
The rotational speed of the rotary cup is a key parameter for paint atomization, and the centrifugal force generated by the high-speed rotation of the rotary cup causes the paint to atomize very finely (50-100 μ m). The smaller the diameter of the paint droplet, the smoother the paint film, the smaller the orange peel effect, and the higher the gloss.
The setting of the rotation speed is also related to the type of paint. The rotation speed of the colored paint is relatively small, while the rotation speed of the intermediate coat and clear coat is relatively high. The speed and flow rate are also related.
If the flow rate is high, the speed should be increased to achieve better atomization effect. However, if the speed is too high, the paint sprayed onto the object will be relatively dry, which can lead to orange peel problems.
In electrostatic spraying, the coated object is the positive electrode and the rotary cup is the negative electrode. After applying a high voltage between the two electrodes, a strong electric attraction force is generated, which causes the atomized paint mist particles to be transferred to the surface of the coated object. The magnitude of high voltage affects the electrostatic effect, painting rate, and uniformity of the paint film in electrostatic spraying.
Flow rate, rotational speed, molding air, and high pressure directly affect the quality of film formation and also affect the utilization rate of paint. In production, adjustments should be made based on the characteristics of the paint and the parameters of the atomizer. The four parameters should be comprehensively considered and continuously optimized in order to achieve the desired spraying effect.
As an important component of modern manufacturing, spray painting robots are leading the transformation and development of the painting industry with their unique advantages. With the continuous advancement of technology and the continuous expansion of application fields, spray painting robots will play a more important role in the future, creating a better living space for humanity.