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Robotic spray painting path planning for complex surface: boundary fitting approach

Published online by Cambridge University Press:  14 February 2023

Hongrui Wu
Affiliation:
School of Mechanical Engineering, Sichuan University, Chengdu, P.R. China
Qing Tang*
Affiliation:
School of Mechanical Engineering, Sichuan University, Chengdu, P.R. China
*
*Corresponding author. E-mail: tangqing_scu@163.com
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Abstract

Currently, most of the robot path planning methods for spray painting are based on slicing the Computer-Aided Design model of the target surface to generate a series of path points. They usually neglect the geometric boundary of the model and the smoothness of the generated path, leading to a non-uniform coating thickness. To ameliorate it, an improved “boundary fitting approach” is proposed. In this method, the upper and lower boundaries of the target surface are firstly detected based on the topology of the stereolithography model. For each pass, several sample points are extracted with a uniform length interval from the intersection points generated by the basic slicing method. The path pass is then described by a fourth-order polynomial curve. It fits the boundary points and sample points for the $z$-$t$ and $y$-$t$ relationships, respectively. Based on the spray gun’s motion direction and spray direction, the orientation of each path point is also defined. The parameters of the path pass are optimized by particle swarm optimization to get the optimal uniformity of the resulting coating thickness. Both of the global uniformity and the local uniformity between two adjacent passes are considered. The strength of the proposed approach is validated by comparing the simulation with the basic and other typical algorithms. The results denote that boundary fitting approach could improve the uniformity of coating thickness. It brings about a better performance for the painted workpiece.

Information

Type
Research Article
Copyright
© The Author(s), 2023. Published by Cambridge University Press
Figure 0

Figure 1. Outline of basic slicing algorithm.

Figure 1

Figure 2. Instant model. The left figure illustrates the standard thickness distribution and the right figure depicts the projection from the standard plane to an arbitrary surface point.

Figure 2

Figure 3. Dynamic model.

Figure 3

Figure 4. Overview of boundary fitting approach.

Figure 4

Figure 5. Boundary point detection. (a) Boundary point extraction. (b) Segmentation.

Figure 5

Figure 6. Sample point generation. Key points are searched with a uniform length interval. The right vertex of Segment 8 is selected as the key point because the accumulative length until Segment 8 just exceeds the length interval and is closer to it than the former one.

Figure 6

Figure 7. $z$-$t$ and $y$-$t$ polynomial curves. $x(t)=t$.

Figure 7

Figure 8. Definition of {Path}.

Figure 8

Figure 9. Two overlapped thickness distributions.

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Figure 10. Factors in the optimization. The current pass is Pass 2. $H$ is an array stores spray distance of each sample point on the current pass, $v$ is the spray speed of the current pass, and $d$ is the spacing distance between the current pass and the last pass.

Figure 10

Table I. Parameters of the thickness calculation model.

Figure 11

Table II. Parameters of spray painting.

Figure 12

Figure 11. Generated path and resulting thickness for concave surface. (a) Boundary fitting approach. (b) Basic approach. (c) Zeng et al. [13]’s approach. (d) Guan and Chen [11]’s approach.

Figure 13

Figure 12. Generated path and resulting thickness for convex surface. (a) Boundary fitting approach. (b) Basic approach. (c) Zeng et al. [13]’s approach. (d) Guan and Chen [11]’s approach.

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Table III. Results of uniformity indicators.

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Table IV. Parameters of optimization methods.

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Table V. Results of the optimization method comparison.