CN109093619B - Robot track planning method for uniform thermal spraying of curved surface - Google Patents
Robot track planning method for uniform thermal spraying of curved surface Download PDFInfo
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- CN109093619B CN109093619B CN201810789818.4A CN201810789818A CN109093619B CN 109093619 B CN109093619 B CN 109093619B CN 201810789818 A CN201810789818 A CN 201810789818A CN 109093619 B CN109093619 B CN 109093619B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
Abstract
A robot track planning method for uniform thermal spraying of a curved surface belongs to the technical field of thermal spraying. The technical scheme of the invention is as follows: aiming at the thickness of the coating on the spherical surface in the normal direction, carrying out research based on the uniform distribution of the coating on the spherical surface, and constructing a coating thickness model; and controlling the spray gun to do uniform variable speed motion along the spherical surface meridian, determining the rotation angle of the spray gun, and controlling the spray gun to rotate through the angle in sequence until the thermal spraying of the surface of the whole spherical surface workpiece is completed, so as to obtain a coating with better uniformity. The invention is not only limited to the spraying of spherical surfaces, but also is suitable for the thermal spraying of large-curvature curved surface workpieces such as non-complete spherical surfaces and the like. The spraying scheme provided by the invention reduces the cost, and has important significance and application value for improving the operation efficiency.
Description
Technical Field
The invention belongs to the technical field of thermal spraying, and particularly relates to a robot trajectory planning method for uniform thermal spraying of a curved surface.
Background
Thermal spraying is one of the important subjects of surface engineering and is an important surface protection technology in the industrial product manufacturing industry. Thermal spraying is a coating technique in which a powdery, filamentous or rod-shaped material is heated to a molten or semi-molten state by a certain heat source (such as an electric arc, a combustion flame, etc.), and then atomized by the power of a flame stream or an externally applied high-speed gas stream and sprayed onto the surface of a pretreated base material at a certain speed to be combined with the base material to form a surface having various functions.
In the early application of the thermal spraying technology, when the surface of a workpiece is sprayed, an operator mainly holds a spray gun to operate, and the spraying material is often accompanied by high temperature, high pressure, noise, arc light, toxic gas and the like in the melting and spraying processes, so that adverse effects can be caused on the health of a human body; meanwhile, as the operator holds the spray gun for spraying, the control accuracy of the spraying motion track is low, and the coating quality is difficult to ensure. With the development of automation technology, handheld spraying is gradually replaced by clamping and spraying of a robot or a specific automatic spraying tool.
At present, in the field of thermal spraying, a spraying robot trajectory planning technology based on a plane and a curved surface with small curvature has been intensively researched, and the trajectory planning is carried out on a large curvature or an irregular curved surface such as a spherical surface and the like so as to obtain a coating with better uniformity. In actual production, the curvature of the curved surface of some industrial parts is large, the traditional method of spraying the curved surface into a plurality of planes by slicing is tedious, the performance of the coating is difficult to ensure, and the uniformity and the attractiveness of the coating are seriously influenced.
Disclosure of Invention
The invention aims to solve the technical problem of providing a robot track planning method for uniform thermal spraying of a curved surface aiming at the defects of the background technology.
The technical scheme adopted by the invention is as follows: a robot track planning method for uniform thermal spraying of a curved surface is characterized by comprising the following steps: the method comprises the following steps:
the method comprises the following steps: selecting a sprayed spherical curved surface workpiece and a spraying powder material;
step two: establishing a model of a spherical workpiece to be sprayed and a spherical curved surface coordinate system based on the radius of the spherical curved surface, and describing the thickness of a coating on a substrate in the normal direction; based on the characteristic that the deposition of spraying powder on the surface of a workpiece in the thermal spraying process has probability distribution, the distribution of a coating basically shows the trend of thick middle and thin edge, a Gaussian model is used as an empirical formula to establish a mathematical model of the thickness of the coating, and the coating profile is drawn;
step three: based on parameters in a spherical coordinate system
The spray gun is along
With uniform acceleration in decreasing direction and with the same acceleration magnitude
The increasing direction makes uniform deceleration movement, namely the spray gun always carries out uniform speed change spraying along the meridian of the spherical curved surface;
step four: selecting the largest angle capable of ensuring the overlapping of the coatings on the adjacent warps, namely the angle corresponding to the arc length of the single coating, as the rotation angle of spray gun spraying based on the radius of the spherical curved surface and the distribution range of Gaussian distribution, and finishing the spraying of the whole surface;
step five: solving and fitting the thickness of the coating in the normal direction of the substrate under the rotation angle and the final coating profile based on a numerical analysis and calculation method;
step six: taking the angle corresponding to the arc length of the single coating as the maximum spray gun rotation angle, reducing the angle in sequence, repeating the fourth step to the fifth step, and researching the coating thickness and the coating profile under different spray gun rotation angles;
step seven: calculating and analyzing the thickness of the corresponding coating in the normal direction and the uniformity of the coating according to the coating profiles obtained under different spray gun rotation angles, and selecting the maximum value of the spray gun rotation angle within the actually allowed coating thickness error range based on the coating thickness requirement;
step eight: generating a spraying track of the robot based on the optimal spray gun rotating angle obtained in the last step, and completing the simulation of the spray gun track in a virtual simulation environment to form a program language of the spraying robot;
step nine: and carrying out thermal spraying on the object according to the steps and the determined spraying track.
Further, in the second step, a coating profile model on the spherical curved surface workpiece is established in MATLAB.
Further, in the second step, the mathematical model equation of the coating thickness is as follows:
wherein r is the radial distance, namely the distance from the coordinate origin to any point on the coating;
theta is an azimuth angle, namely an included angle between a projection line of a connecting line of an origin and any point on the coating on an XY plane and a positive X axis;
σ — standard deviation, representing the degree of dispersion of the gaussian distributed data;
r-radius of the sphere;
a-constant coefficient influencing the coating thickness is determined by factors such as spraying distance, moving speed of a spray gun and the like;
v0-initial velocity of the lance;
a, acceleration of the spray gun;
alpha-the arc through which the lance turns as it moves along the warp.
Further, according to the known mathematical model of the coating thickness, 3000-5000 parameters theta and theta are sequentially selected in the interval where the coating profile is located
And (3) analyzing the normal thickness of the coating at each position by interpolation calculation.
Further, in the fifth step, the coating thickness at each position is respectively overlapped in the normal direction, and a final coating profile is fitted.
Further, in the ninth step, when the physical workpiece is sprayed, the number of spraying times is calculated according to the required coating thickness.
The coating thickness calculated by the invention is always the coating thickness in the normal direction, the spray gun is controlled to move along the meridian line of the sphere at a uniform variable speed all the time, and then the selected angle is taken as the optimal rotation angle of the spray gun to rotate through the angle in sequence until the spraying of the whole workpiece surface is finished, so that the uniformity of the coating is better ensured. The invention is not limited to the thermal spraying of spherical surfaces, but also is suitable for the thermal spraying of other large-curvature curved surface workpieces. The spraying scheme provided by the invention reduces the cost, and has important significance and application value for improving the operation efficiency.
The invention has the beneficial effects that: based on a uniform thermal spraying method for the surface of a spherical curved surface, the uniformity of a coating can be effectively improved, and the problem that the workpiece cannot be subjected to rotary spraying when the surface of the workpiece is a large-curvature curved surface such as an incomplete spherical surface in the spraying operation is solved. Meanwhile, the cost of practical operation is reduced, and the working efficiency is improved.
According to the invention, aiming at the thickness of the coating on the spherical surface in the normal direction, the research based on the uniform distribution of the coating on the spherical surface is developed, and a coating thickness model is constructed; and controlling the spray gun to do uniform variable speed motion along the spherical surface meridian, determining the rotation angle of the spray gun, and controlling the spray gun to rotate through the angle in sequence until the thermal spraying of the surface of the whole spherical surface workpiece is completed, so as to obtain a coating with better uniformity. The robot spraying is widely applied in the fields of national defense and civil industry, so that the technology has wide market prospect and economic benefit.
Drawings
FIG. 1 is a schematic diagram of a spherical model established by the robot trajectory planning method for uniform thermal spraying of curved surfaces according to the invention;
FIG. 2 is a schematic diagram of a coating profile generated by a spray gun moving at a uniform speed along a meridian line according to the robot trajectory planning method for uniform thermal spraying of curved surfaces of the present invention;
FIG. 3 is a schematic diagram of a coating profile generated based on a gun rotation angle of 0.30rad established by a robot trajectory planning method for curved surface uniform thermal spraying according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a coating profile superimposed in the normal direction based on the coating thickness fitted at a gun rotation angle of 0.30rad established by a robot trajectory planning method for curved surface uniform thermal spraying according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a coating profile generated based on a gun rotation angle of 0.15rad established by a robot trajectory planning method for curved surface uniform thermal spraying in an embodiment of the present invention;
FIG. 6 is a schematic diagram of a coating profile superimposed in the normal direction based on the coating thickness fitted at a gun rotation angle of 0.15rad established by a robot trajectory planning method for curved surface uniform thermal spraying according to an embodiment of the present invention;
FIG. 7 is a schematic diagram of a coating profile generated based on a gun rotation angle of 0.10rad established by a robot trajectory planning method for curved surface uniform thermal spraying in an embodiment of the present invention;
fig. 8 is a schematic diagram of a coating profile superimposed in a normal direction of a coating thickness fitted based on a 0.10rad rotation angle of a spray gun, which is established by a robot trajectory planning method for curved surface uniform thermal spraying according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The embodiment based on the invention belongs to the protection scope of the invention.
A robot track planning method for curved surface uniform thermal spraying comprises the following steps (taking a group of parameters as an example):
(1) the powder used for spraying is NiCrBSi powder with the particle size range of 40-75 mu m, the sprayed spherical workpiece is a stainless steel ball, and the spherical radius R is 100 mm; the coating thickness coefficient A is 22, the distance h from the spray gun to the substrate is 120mm, and the initial speed of the spray gun is the speed v on the equatorial plane of the spherical surface0113mm/s and 100mm/s2。
(2) Based on the radius R of the sphere being 100mm, the spraying distance h being 120mm and the arc length l of the coating formed by the spray gun on the substrate being 30mm, the maximum angle 0.3rad at which the coatings on adjacent warps can be superimposed is selected as the rotation angle of the spray gun, and in order to obtain a larger coating thickness, the number of spraying times is set to 4.
(3) And constructing a model of the spherical workpiece to be sprayed, establishing a spherical coordinate system, and describing the thickness of the coating on the substrate in the normal direction.
(4) Based on the characteristic that the deposition of the spraying powder on the surface of the workpiece has probability distribution in the thermal spraying process, the distribution of the coating basically shows the trend of thick middle and thin edge, a Gaussian model is used as an empirical formula to establish a mathematical model of the thickness of the coating, and the coating profile is drawn.
(5) Based on parameters in a spherical coordinate system
The spray gun is along
Uniform acceleration of the gun from the equatorial plane along one meridian of the sphere, a mathematical model of the coating profile:
(6) substituting the data in the steps (1) and (2) according to the calculation formula in the step (5), and selecting 3600 parameters theta and theta in the interval where the coating profile is located
And (3) analyzing the normal thickness of the coating at each position by interpolation calculation.
(7) After the spray gun sprays along a meridian, the spray gun is controlled to rotate 0.3rad around the center of the sphere and move along the same acceleration
The increasing direction makes uniform deceleration movement until the spraying of the whole substrate surface is completed.
(8) And respectively accumulating the coating thickness at each position in the normal direction to fit a final coating profile.
(9) Selecting the rotation angle to be 0.15rad, setting the spraying times to be equal to 4, and repeating the steps (7) to (8).
(10) Selecting the rotation angle to be 0.10rad, setting the spraying times to be equal to 2, and repeating the steps (7) to (8).
(11) And analyzing and calculating the maximum and minimum normal thicknesses of each fitted final coating profile, and selecting the optimal spray gun rotation angle based on the coating thickness requirement and the actually allowed coating thickness error.
(12) And deriving parameters influencing the spraying track, such as spraying distance, speed of the spray gun relative to the substrate, rotation angle of the spray gun and the like, and forming a program language of the spraying robot.
(13) And spraying the real object according to the steps and the determined spraying track.
Based on the invention, the uniformity of the coating can be effectively improved, and the problem that the workpiece can not be subjected to rotary spraying when the surface of the workpiece is a large-curvature curved surface such as an incomplete spherical surface in the spraying operation is solved. Meanwhile, the cost of practical operation is reduced, and the working efficiency is improved.
The foregoing is a preferred embodiment of the present invention.
Claims (4)
1. A robot track planning method for uniform thermal spraying of a curved surface is characterized by comprising the following steps:
the method comprises the following steps: selecting a sprayed spherical curved surface workpiece and a spraying powder material;
step two: establishing a model of a spherical curved surface workpiece to be sprayed and a spherical curved surface coordinate system based on the radius of the spherical curved surface, and describing the thickness of a coating on a substrate in the normal direction; based on the characteristic that the deposition of spraying powder on the surface of a workpiece in the thermal spraying process has probability distribution, the distribution of a coating basically shows the trend of thick middle and thin edge, a Gaussian model is used as an empirical formula to establish a mathematical model of the thickness of the coating in MATLAB, and the coating profile is drawn; the mathematical model equation for the coating thickness is:
wherein r is the radial distance, namely the distance from the coordinate origin to any point on the coating;
theta is an azimuth angle, namely an included angle between a projection line of a connecting line of an origin and any point on the coating on an XY plane and a positive X axis;
σ — standard deviation, representing the degree of dispersion of the gaussian distributed data;
r-radius of the sphere;
a-constant coefficient influencing the coating thickness is determined by factors such as spraying distance, moving speed of a spray gun and the like;
v0-initial velocity of the lance;
a, acceleration of the spray gun;
alpha-the radian of the spray gun rotating when moving along the meridian;
step three: based on parameters in a spherical coordinate system
The spray gun is along
With uniform acceleration in decreasing direction and with the same acceleration magnitude
The increasing direction makes uniform deceleration movement, namely the spray gun always carries out uniform speed change spraying along the meridian of the spherical curved surface;
step four: selecting the largest angle capable of ensuring the overlapping of the coatings on the adjacent warps, namely the angle corresponding to the arc length of the single coating, as the rotation angle of spray gun spraying based on the radius of the spherical curved surface and the distribution range of Gaussian distribution, and finishing the spraying of the whole surface;
step five: solving and fitting the thickness of the coating in the normal direction of the substrate under the rotation angle and the final coating profile based on a numerical analysis and calculation method;
step six: taking the angle corresponding to the arc length of the single coating as the maximum spray gun rotation angle, reducing the angle in sequence, repeating the fourth step to the fifth step, and researching the coating thickness and the coating profile under different spray gun rotation angles;
step seven: calculating and analyzing the thickness of the corresponding coating in the normal direction and the uniformity of the coating according to the coating profiles obtained under different spray gun rotation angles, and selecting the maximum value of the spray gun rotation angle within the actually allowed coating thickness error range based on the coating thickness requirement;
step eight: generating a spraying track of the robot based on the optimal spray gun rotating angle obtained in the last step, and completing the simulation of the spray gun track in a virtual simulation environment to form a program language of the spraying robot;
step nine: and carrying out thermal spraying on the object according to the steps and the determined spraying track.
2. The method for planning the trajectory of a robot for curved surface uniform thermal spraying according to claim 1, wherein the method comprises the following steps: according to a known mathematical model of the thickness of the coating, 3000-5000 parameters theta and theta are sequentially selected in the region where the coating profile is located
And (3) analyzing the normal thickness of the coating at each position by interpolation calculation.
3. The method for planning the trajectory of a robot for curved surface uniform thermal spraying according to claim 1, wherein the method comprises the following steps: and step five, respectively accumulating the coating thickness at each position in the normal direction, and fitting to obtain a final coating profile.
4. The method for planning the trajectory of a robot for curved surface uniform thermal spraying according to claim 1, wherein the method comprises the following steps: in the ninth step, when the physical workpiece is subjected to thermal spraying, the number of times of spraying is calculated according to the required coating thickness.
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| CN112691864B (en) * | 2020-11-27 | 2022-05-10 | 成都飞机工业（集团）有限责任公司 | Method for improving coating thickness uniformity of automatic spraying coating |
| CN113106440A (en) * | 2021-04-21 | 2021-07-13 | 西安交通大学 | Appearance control method of cold spraying additive manufacturing component |
| CN114798255A (en) * | 2022-05-25 | 2022-07-29 | 湖南恒岳重钢钢结构工程有限公司 | Method and system for continuously and uniformly spraying inner wall of variable-diameter pipeline |
| CN115889121B (en) * | 2022-12-09 | 2023-12-22 | 东方电气集团东方汽轮机有限公司 | Large-area uniform spraying method for complex special-shaped gas turbine blade coating |
| CN117380498A (en) * | 2023-12-11 | 2024-01-12 | 太仓中集特种物流装备有限公司 | Container spraying method and container spraying system |
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