Intelligent painting process planner for robotic bridge painting

Due to increased government regulations on environment, health, and safety, the cost of on-site bridge painting has quadrupled over the past several years. The construction industry faces a great challenge in how to control the increased costs of bridge painting and meet the regulations at the same time. A possible solution to address this challenge is to develop a robotic bridge painting system. The development of the robotic system can be justified by the potential improvements in safety and productivity. This paper presents the development and testing of an Intelligent Painting Process Planner. The Planner, built based on bridge feature scheme, is the key component for the robotic bridge painting system that integrates the painting process planning, robot path planning, cost optimization, and quality control functions. During the development process, lab experiments were conducted to determine the values of painting process planning parameters and coating thickness distribution functions. Field tests demonstrated that the prototype robotic bridge painting system achieved the specified painting quality using the parameter values provided by the Planner. Areas that need to be improved in the future were also identified.