METALS AND ENGINEERING CORPORATION

BISHOFTU AUTOMOTIVE ENGINEERING INDUSTRY

AUTOMATIC
SPRAY
PAINTER
 1.INTRODUCTION
 The design and fabrication of an automatic paint spraying machine is
important with the foundation of simplicity, reducing human effort,
improve the quality, accuracy and constant painting.
 The biggest advantage of automation is that it is used to reduce human
effort, improve the quality, precision and accuracy.
 This automatic car painting machine is not designed using complicated
components. This painting is simple and portable.
 In this project we use scissor lift mechanism to lift the paint gun so that
the paint is applied to the entire height of the vehicle. The paint gun is
actuated by pneumatic cylinder. The process is controlled by the
control unit.
 2. Problem Statement
 In the painting shop the chemicals can cause hazards
to the painters such as eye and respiratory system
problems. Also the nature of painting procedure that
requires repeated work and hand rising makes it
boring, time and effort consuming.
 And also the painter distance is not uniform when
we apply paint manually. This reduces the quality
and accuracy of painting. Therefor it is necessary to
know the distance between the nozzle and work
piece. That is, if the nozzle is too close, paint
accumulates and causes issues like runs drips and
sags, if it is too far away, too much paint is wasted to
surrounding areas.
 Those factors motivate the development of the paint
booth automation system.
Thus we try to present the automatic painting device as a
solution to the drawbacks of the traditional system.
It would offer the opportunity to reduce or eliminate human
exposure to difficult and hazardous , which would solve most
of the problems connected with safety when many activities
occur at the same time.
 3.Objectives
3.1 General objective
To design and analysis an automatic spray painter machine.
3.2 Specific objectives
 To design a scissor lift with approximate maximum hieght
of 4 meter
 To design a one DOF base to carry the lift and remaining
part
 A code controlling the solenoid valve of the pneumatic
actuator
 To design hydraulic actuator for the scissor lift mechanism
 CHAPTER TWO
literature review

 The related works detailed in this section was conducted to

ascertain and understand the success and failure of painting
system that have been designed before.
 [1]: In this paper author describe the design and working of
an autonomous painting device. The conceptual design of a
movable painting machine to be used for painting interior
walls of residential building had been described. It uses roller
fed with liquid paint and keeps contact with the wall surface.
The machine enables the roller to scan vertically as well as
horizontally to the painted walls.
 chapter three
Methodology
 This design to make automatic paint spraying machine by following the
correct procedure of design analysis and interpretation. And also data can
be analyzed from secondary and primary source.
 This include collecting data from primary sources like፦
 Observation
 Measurement
 Asking question
 And secondary data like፦
 Website
 Manual reading
 literature review
 Data analysis
 The data analysis work will be done using mathematical formula, concept
analysis and software support analysis including
 Under taking weight and actuator force
 Undertake take detail analysis for the components
 Using diagram and CATIA software analysis of part.
 [2]: this paper gives basic information about small and
medium scale industries manufacturing components have
to paint for protecting from rusting so the spray application
consumes maximum time and paint which required the
skilled worker emerged with the application. They cannot
manage the arrangements for higher efficiency so the rise
of the such process have to be made which is affordable,
gives better accuracy, consumes minimum time for coating
so objective has to developed such mechanism which coat
the object with the dipping technique having semi-
automatic arrangement which is suitable for our
requirement and which can be valuable for small and
medium scale industries.
Component that we use in the design analysis
1. Battery : - In order to provide supply to the controller unit battery is
used. Lead acid battery is used in this project.
2. Control unit: - It controls the pneumatic cylinders extension and
retraction, based on the IR sensors output and the power button
input.
3. IR sensor : - IR sensor is used for this project. IR (Infrared) is the
typical light source being used to detect painting object. The basic
principle of IR sensor is based on an IR emitter and an IR receiver. IR
emitter will emit infrared continuously when power is supplied to it.
On the other hand, the IR receiver will be connected and perform
the task of a voltage divider.
IR Sensor Features:
· Input voltage: 5VDC
· Sensing Range: 15cm
· Output signal: analog voltage
· Emitting element: Infrared LED
4. Single Acting 3/2 Solenoid Valve
A solenoid is an electrical device that converts electrical energy into straight
line motion and force. The Solenoid control valve is used to control the flow
direction is called cut off valve or solenoid valve. This solenoid cut off valve is
controlled by the electronic control unit.
5. DC motor: - DC motors are widely used in speed and direction control
because control of these motors are easier than other motors.
Specification of DC motor used in this project is mentioned as follows:
 Voltage – 12v
 Load speed – 120 rpm
 Load current – 1400 mA
 Power – 17 watt
6. Single acting pneumatic cylinder: - In this project
single acting cylinders is used. The cylinder is used for the
paint sprayer actuation.
If the object is detected by the IR sensor it sends the signal
to the control unit and the control unit sends the actuation
signal to the pneumatic cylinder. The actuation of these
cylinders causes the paint sprayer actuation .If the
maximum height reached or if the IR sensor not detect the
object presence it immediately stop sending signals to the
control unit. Then the. pneumatic cylinders retract back to
its original position.
7. Double acting hydraulic cylinder: - it provides a force
for the up and down movement of the scissor lift.
8. Flow control valve: - used to control the flow of
hydraulic fluid to the cylinder.
9. Scissor lift : - used to support the pneumatic cylinder &
the gun and move the spray gun in the Z direction.
10. Wheels : - used to move the spray gun with the scissor lift
in the X&Y direction with the help of the dc motors.
11, Electrical and electronics system.
Mechanism: - A scissors lift uses linked, folding supports in a
criss-cross 'X' pattern, known as a pantograph. The extension
is achieved by applying pressure to the outside of a set of
supports located at one end of the lift, elongating the
crossing pattern. This can be achieved through a double
acting hydraulic cylinder.
 RESULT AND CONCLUSION
 The main idea of this project is to reduce the human
interference in the painting process of the automotive
industry is successfully done.
 The automated painting process with less human
interference results improvement in accuracy and the
quality of the painting is enhanced. The number of
workers needed per paint booth is reduced by one
since the worker only has to handle the system.
 CONCLUSION
 The painter automatic paint system has achieved optimum
benefits with regard to reliability, safety appearance, and
ease of use. Automatically paint the vehicle of a given
dimensions has been designed and implemented which is
applicable up to 4m height.
 The approach use IR sensors to measure distance and
provide feedback to the controller which in turn controls
the actuator. The prototype was designed for the purpose of
automating the painting process in automotive industry,
making it easier and more efficient.