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Article information:
To cite this document:
Heping Chen Thomas Fuhlbrigge Xiongzi Li, (2009),"A review of CAD-based robot path planning for spray painting", Industrial
Robot: An International Journal, Vol. 36 Iss 1 pp. 45 - 50
Permanent link to this document:
http://dx.doi.org/10.1108/01439910910924666
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Research article
Robotics and Automation Laboratory, ABB Corporate Research Center, Windsor, Connecticut, USA
Abstract
Purpose Paint path planning for industrial robots is critical for uniform paint distribution, process cycle time and material waste, etc. However, paint
path planning is still a costly and time-consuming process. Currently paint path planning has always caused a bottle-neck for manufacturing automation
because typical manual teaching methods are tedious, error-prone and skill-dependent. Hence, it is essential to develop automated tool path-planning
methods to replace manual paint path planning. The purpose of this paper is to review the existing automated tool path-planning methods, and
investigate their advantages and disadvantages.
Design/methodology/approach The approach takes the form of a review of automated tool path-planning methods, to investigate the advantages
and disadvantages of the current technologies.
Findings Paint path planning is a very complicated task considering complex parts, paint process requirements and complicated spraying tools. There
are some research and development efforts in this area. Based on the review of the methods used for paint path planning and simulation, the paper
concludes that: the tessellated CAD model formats have many advantages in paint path planning and paint deposition simulation. However, the
tessellated CAD model formats lack edge and connection information. Hence, it may not be suitable for some applications requiring edge following,
such as welding. For the spray gun model, more complicated models, such as 2D models, should be used for both path planning and paint distribution
simulation. Paint path generation methods should be able to generate a paint path for complex automotive parts without assumptions, such as
presupposing a part with a continuous surface.
Practical implications The paper makes possible automated path generation for spray-painting process using industrial robots such that the pathplanning time can be reduced, the product quality improved, etc.
Originality/value The paper provides a useful review of current paint path-planning methodologies based on the CAD models of parts.
Keywords Robotics, Control applications, Coating processes, Painting, Computer aided design
Paper type Research paper
1. Introduction
Spray painting is widely used in industry, especially in
automotive. The uniformity of paint thickness on a product
can strongly influence its quality, which is typically
determined by the robot tool path. Robot path planning
with uniform material distribution remains a challenging
research topic in the spray painting processes. Currently, there
are two robot path planning methods: manual and automatic.
Manual robot path planning methods (teaching methods) are
based on manufacturing engineers experience and knowledge
of production facilities, equipment, their capabilities,
processes, and tools. A manufacturing engineer has to carry
out extensive tests on a work cell to improve a tool path in
order to obtain a good paint distribution. This process is
complex and very time-consuming. The results vary based on
The current issue and full text archive of this journal is available at
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The authors would like to thank ABB Corporate Research for funding
their study and their co-worker Gregory Rossano for polishing the paper.
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Height (m)
1.2
1.1
1
0.9
0.8
0.6
0.4
0.2
Width (m)
0.6
0.8
1.4
1.2
Length (m)
1.6
(a)
(b)
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TOP
FRONT
RIGHT
Patch
Figure 6 (a) Tessellated CAD model of the underside of a car hood; (b) the generated robot path
6
4
3
(a)
(b)
Figure 8 The start curve (seed curve) for paint path planning
Starting Curve
Offset Curve
Figure 7 Curve approximation for path planning: (a) the surface is cut
along the u-direction; (b) the intersection curve is approximated using a
straight line
v
(a)
(b)
Note: The center point is a generated path point and the vector is the tool
orientation
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4. Conclusions
Paint path planning is a very complicated task considering
complex parts, paint process requirements and complicated
spraying tools. There are some research and development
efforts in this area. Based on the review of the methods used
for paint path planning and simulation, we have the following
conclusions:
.
The tessellated CAD model formats have many
advantages in paint path planning and paint deposition
simulation. However, the tessellated CAD model formats
lack edge and connection information. Hence, it may not
be suitable for some applications requiring edge following,
such as welding.
.
For the spray gun model, more complicated models, such
as 2D models, should be used for both path planning and
paint distribution simulation.
.
Paint path generation methods should be able to generate
a paint path for complex automotive parts without
assumptions, such as presupposing a part with a
continuous surface.
References
ABB Inc. (n.d.), Virtual Applicator Manual, ABB Inc., Lake
Mary, FL (in press).
Antonio, J.K. (1994), Optimal trajectory planning for spray
coating, Proceedings, 1994 IEEE International Conference on
Robotics and Automation, Vol. 3, May, pp. 2570-7.
Asakawa, N. and Takeuchi, Y. (1997), Teachless spraypainting of sculptured surface by an industrial robot, paper
presented at IEEE Intl Conf. on Robotics and Automation,
Albuquerque, April.
Atkar, P.N., Greenfield, A., Conner, D.C., Choset, H. and
Rizzi, A.A. (2005), Uniform coverage of automotive
surface patches, The International Journal of Robotics
Research, Vol. 24 No. 11, pp. 883-98.
Conner, D.C., Atkar, P., Rizzi, A. and Choset, H. (2002),
Deposition Modeling for Paint Application on Surfaces
Embedded in R^3, Tech. Report CMU-RI-TR-02-08,
Robotics
Institute,
Carnegie-Mellon
University,
Pittsburgh, PA, October.
Conner, D.C., Greenfield, A.L., Atkar, P., Rizzi, A. and
Choset, H. (2005), Paint deposition modeling for
Further reading
Freund, E., Rokossa, D. and Romann, J. (1998), Processoriented approach to an efficient offline programming of
industrial robots, IECON 98: Proceedings of the 24th Annual
Conference of the IEEE Industrial Electronics Society, Aachen,
31 August-4 September, Vol. 1.
Corresponding author
Heping Chen can be contacted at: heping.chen@us.abb.com
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