Nozzle Mounting Method Optimization Based on Robot Kinematic Analysis

Nowadays, the application of industrial robots in thermal spray is gaining more and more importance. A desired coating quality depends on factors such as a balanced robot performance, a uniform scanning trajectory and stable parameters (e.g. nozzle speed, scanning step, spray angle, standoff distance). These factors also affect the mass and heat transfer as well as the coating formation. Thus, the kinematic optimization of all these aspects plays a key role in order to obtain an optimal coating quality. In this study, the robot performance was optimized from the aspect of nozzle mounting on the robot. An optimized nozzle mounting for a type F4 nozzle was designed, based on the conventional mounting method from the point of view of robot kinematics validated on a virtual robot. Robot kinematic parameters were obtained from the simulation by offline programming software and analyzed by statistical methods. The energy consumptions of different nozzle mounting methods were also compared. The results showed that it was possible to reasonably assign the amount of robot motion to each axis during the process, so achieving a constant nozzle speed. Thus, it is possible optimize robot performance and to economize robot energy.