Spraying is another common process application of industrial robots, second only to welding process applications, and they all belong to high-intensity, high-precision, and high-sensitivity work tasks in harsh environments.
The spraying process has extremely high requirements for the performance of the robot, and of course, the formulation of the process and the preparation of the program are also extremely strict, which will directly affect the paint effect of spraying.
Most robots can verify the proposed spraying process through virtual simulation before the real spraying work, and Yaskawa Robotics is no exception, this task can be achieved through its own adapted virtual simulation and offline programming software MotoSimEG-VRC.
When MotoSimEG-VRC software simulates the application of the spraying process, it can not only verify the robot's motion path and interference detection, but also generate a paint atomization model at the nozzle of the spray gun and a paint effect on the surface of the workpiece, which is very helpful for the planning and verification of the spraying process.
Spraying robot system creation
Open the MotoSimEG-VRC software, create a virtual simulation project for the process application of the spraying robot, and generate a virtual simulation environment.
Add a virtual robot system in the virtual simulation environment, select "DX-200" for the robot controller, select any model of the robot in the "MPX" series (all of these series are spraying process application robots), select "PAINT" for process application, and then create a robot system in the "Standard Setting Execute" mode.
Gun models are imported and mounted to the robot
Open the CadTree dialog box, import the robot gun (atomizer) model with the world coordinate system world as the parent reference object, and then use the "Move Parent" shortcut command to modify the gun parent reference object to the robot's "DX200-R01_flange", and at the same time the gun model is installed on the robot's six-axis flange.
Use the "Tool Data" command in the "Controller" menu bar to calibrate the TCP of the robot spray gun tool, you can activate the "Pick Enable" function option in the Tool Editor dialog box, and then directly pick the TCP origin position at the gun nozzle position.
Spraying station peripherals added
Import the spray table model and place it in the appropriate position, then import the spray part model and place it on the surface of the paint table. Of course, the painting table and the painted workpiece model can also be created directly using the model creation function that comes with the software.
Spray simulation settings
The key step in the application simulation of the spraying process is the spraying simulation setup, including the spraying model setup and the spraying setup. Among them, the spraying model is to generate a model that simulates the real spray body at the nozzle of the spray gun, and the shape of the spraying model can be changed by changing the parameters of the spraying model, and the simulated spraying effect will also be changed. In the spraying settings, you can set the object of the workpiece to be painted, the color effect of the spraying, and so on. During the simulation operation, the spraying model can be automatically displayed and hidden through the SPYON and SPYOF commands, and the spraying color effect can be displayed on the motion path between the PYON and SPYOF commands.
Click the "Paint Setting" command button in the menu bar of the software "Simulation" to pop up the Paint Panel dialog box, and activate the Spray model setting attribute label by default, that is, the spray model setting.
The spraying model parameters can be set according to the actual spraying process standard to control the atomization state after the paint is sprayed, so as to achieve the required coating effect.
The following is a detailed description of each function option in the Spray model setting property tab.
Gun No.: Set the gun number, range 1-3.
Tool No.: Specifies the tool number (robot tool number) used to set the gun number.
(a) TCP distance (mm): TCP distance, which refers to the vertical distance between TCP and the spray gun nozzle on the spraying materialization model.
(b) Valid distance (mm): The maximum length of paint sprayed from the nozzle of the spray gun.
(c) Max Diameter (mm): The maximum diameter refers to the maximum width of the paint surface after the paint is atomized.
(d) Mini Diameter (mm): The minimum diameter, which refers to the minimum width of the paint surface after the paint is atomized.
(e) Nozzle Position: Nozzle Position Coordinates, which refers to the relative position coordinates between the spray atomization model and the TCP of the spray gun tool.
(e) Nozzle Posture: Nozzle Posture Coordinates, which refers to the relative attitude coordinates between the spray atomization model and the TCP of the spray gun tool.
TCP calculation: When activated, the tool TCP coordinates will be automatically calculated based on the data entered.
Transparent: When activated, the spray atomization model is generated and displayed in a translucent color.
Model division: Specifies the number of faces for the resulting spray atomization model.
TCP distance: Specifies the model color between the spray gun nozzle and the spray atomization model TCP.
Valid distance: Specifies the color of the model between the TCP of the spraying atomization model and the boundary of the spraying effective range.
Display model: When activated, the resulting spray atomization model is displayed.
In the above parameters, the function options marked with the words a, b, c, d, and e are described in the picture on the right side of the dialog box, which can be used as auxiliary reference.
Click on the "Paint Setting" property tab to switch to the spray setting interface. Activate the "Paint Enable" option, then set the color of the spray effect under the Paint Color ribbon, and finally activate the "Pick" option to select the painted workpiece object in the software workspace and select it in the workpiece model list.
It is important to note here that when there are multiple robots in one controller, spray simulation will not be supported; Spraying simulation cannot directly output 3DPDF files or AVI files; Simulating the same outer coating with multiple guns is also not supported; When using the "Masking" function, the spraying simulation will run slower.
A detailed description of each of the options in the Paint Setting tabs is shown below.
Gun No.: Set the gun number, range 1-3.
Paint Enable: When activated, the set paint color will be displayed on the artifact while the simulation is running.
Pick: After activation, you can directly click on the workpiece model in the software workspace, and the selected model will be displayed in the workpiece model list box below.
A child model is also registered simultaneously: After activation, the child models of the added artifact model will also be registered at the same time.
Paint Color: Set the color of the workpiece, including the color when spraying normally (Top), the color at the beginning of spraying (Bottom), the color at the end of spraying (Over), and the color gradient between the start and end of spraying.
Model List: A list of workpiece models that displays the selected workpiece models and whether the model has been selected.
Check All: When clicked, all models in the workpiece model list are selected.
Clear All: When clicked, all selected models in the workpiece model list will be unchecked.
Masking: When activated, the paint color will not be displayed on the part model if there is an obstacle between the selected workpiece model and the gun.
Del: Click to remove the selected workpiece model from the workpiece model list.
Add from CadTree: When clicked, the selected model will be added from the CadTree to the workpiece model list.
Robot teach-in programming
In the virtual teach pendant, the robot spraying running trajectory program is written, and the spraying start instruction PYON and the spraying end instruction SPYOF are added before and after the spraying process path program segment, as shown in the following figure.
Spraying robot simulation operation
The spraying robot is simulated and operated, and the simulation operation effect is shown in the dynamic diagram below. It can be seen that the robot moves according to the teach-in trajectory point and sprays the workpiece, and the surface of the workpiece sprayed by the robot immediately shows the set paint color.
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