Automation For Spray Painting

A
Project

Review report
On

Automation For Spray Painting

 Automation For Spray Painting

Abstract

Painting is the practice of applying paint, pigment, colour or other medium to a surface (support
base). The medium is commonly applied to the base with a brush but other objects can be used.
In art, the term painting describes both the act and the result of the action. However, painting is
also used outside of art as a common trade among craftsmen and builders. Paintings may have
for their support such surface as walls, paper, canvas, wood, glass, lacquer, clay, leaf, copper
or concrete, and may incorporate multiple other materials including sand, clay, paper, gold leaf
as well as objects.
Currently automated robot path planning has always caused a bottleneck for the spray
painting processes because typical manual teaching methods are time consuming, error-prone
and skill dependent. Thus, it is essential to develop automated tool path planning methods to
replace manual tool path planning ones in order to reduce the cost and improve product quality.
This challenging research has been receiving more and more attention from both academia and
industry.
The painting chemicals can cause hazards to the human 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. When construction workers and
robots are properly integrated in building tasks, the whole construction process can be better
managed and savings in human labour and timing are obtained as a consequence. In addition, it
would offer the opportunity to reduce or eliminate human exposure to difficult and hazardous
environments, which would solve most of the problems connected with safety when many
activities occur at the same time. These factors motivate the development of an automated
robotic painting system.
 Automation For Spray Painting

Introduction

Automation is a process whereby the processes, where labor is used on big scale can be reduced
resulting into better quality of product, more accuracy and less time consuming. It increases the
Production of the good quality components following the increase in demand due to automation.
Company which produces various types of components used in various industries suffers
problem for applying color due to lack of technology. The company needs solution by which
workers can color the components easier, economical and efficient. Company having
manufacturing unit which produces various types of job or components as per demand. This
company produces the components related to various industries like textile industries,
automobile industries and other industries. So they paint the components by two ways. By
applying color to the components with help of worker that’s mean manually. And that’s why the
quality and the finishing of the color is not so good. And also manually coloring process take
more time. Second method is, by sending the components to the other industry. However they
can get good quality and good finishing of the components, it takes lots of expanses for loading,
transporting, unloading etc.
 Automation For Spray Painting

II. Methods for Applying Paint or Coat.

2.1 Dipping
The application of finishes by dipping is generally confined to factories or large repair stations.
The process consists of dipping the part to be finished in a tank filled with the finishing material.
Primer coats are frequently applied in this manner.

2.2 Brushing
Brushing has long been a satisfactory method of applying finishes to all types of surfaces.
Brushing is generally used for small repair work and on surfaces where it is not practicable to
spray paint. The material to be applied should be thinned to the proper consistency for brushing.
A material that is too thick has a tendency to pull or rope under the brush. If the materials are too
thin, they are likely to run or not cover the surface adequately. Proper thinning and substrate
temperature allows the finish to flow-out and eliminates the brush marks.

2.3 Spraying
Spraying is the preferred method for a quality finish. Spraying is used to cover large surfaces
with a uniform layer of material, which results in the most cost effective method of application.
All spray systems have several basic similarities. There must be an adequate source of
compressed air, a reservoir or feed tank to hold a supply of the finishing material, and a device
for controlling the combination of the air and finishing material ejected in an atomized cloud or
spray against the surface to be coated. A self-contained, pressurized spray can of paint meets the
above requirements and satisfactory results can be obtained painting components and small areas
of touchup. However, the aviation coating materials available in cans is limited, and this chapter
addresses the application of mixed components through a spray gun. There are two main types
of spray equipment. A spray gun with an integral paint container is adequate for use when
painting small areas. When large areas are painted, pressure feed equipment is more desirable
since a large supply of finishing material can be applied without the interruption of having to
stop and refill a paint container. An added bonus is the lighter overall weight of the spray gun
and the flexibility of spraying in any direction with a constant pressure to the gun. The air supply
 Automation For Spray Painting

to the spray gun must be entirely free of water or oil in order to produce the optimum results in
the finished product. Water traps, as well as suitable filters to remove any trace of oil, must be
incorporated in the air pressure supply line. These filters and traps must be serviced on a regular
basis.

III. Miscelleneous painting Tools and Equipment.

Some tools that are available to the painter include:

 Masking paper/tape dispenser that accommodates various widths of masking paper. It
includes a masking tape dispenser that applies the tape to one edge of the paper as it is
rolled off to facilitate one person applying the paper and tape in a single step.
 Electronic and magnetic paint thickness gauges to measure dry paint thickness.
 Wet film gauges to measure freshly applied wet paint.
 Infrared thermometers to measure coating and substrate surfaces to verify that they fall in
the recommended temperature range prior to spraying.
 Automation For Spray Painting

Literature Survey

Seth Berrier et al [1] In this paper authors describes a computer graphics program that has been
developed to overcome some of the limitations of the orthodox colour fan deck. A computer
graphic program for organizing and displaying the colours in a paint collection is presented. A
virtual representation for the traditional colour card fan deck is described. This interactive
program provides a lightness, chroma and hue interface for selecting a colour from the
collection. Software for visualizing a paint colour on a three dimensional surface is also
discussed. This tool allows the user to evaluate the sheen of a solid paint colour and the travel of
a metallic or pearlescent paintcolour. In this paper a novel interface was presented that allows to
navigate through the colour cards of a traditional fan deck.

Nordson Corporation [2] Most paint application systems are unique and designed for a
particular manufacturing process and/or finish requirement. Selecting the best finishing method
to meet both the technical and economic requirements for a specific system requires a careful
evaluation of many factors. When compared to conventional air spray, airless spray applications
can provide a higher transfer efficiency in a finishing operation. In many applications airless can
provide maximum material utilization and reduced operating costs. For finishers, this translates
into superior finishing quality and optimum cost effectiveness, making it the efficient choice for
many of today’s liquid painting applications as shown in figure 1.

Figure 1: Conventional air spray creates a “cloud” as high-pressure air jets atomize
coatings.
 Automation For Spray Painting

As coting particles are blown at high speed toward the part, many are dispersed into the
air. As due to high velocity air combined with coating particles creates cloud as they
bounce off part resulting of wastage of paint with lower painting efficiency as given below
in figure.2.

Figure 2: Bounce of Paint & Overspray due to large volume of air.

Application Guide by Createx Distribution [3] This paper gives basic information and
environmental condition about paint like recommended painting conditions: 70º F or higher in a
dry, dust-free environment. When painting in humid or colder conditions, allow for extended
drying time. Use of air decreases drying time and is recommended as the primary means to cure
paint. Heat may also assist curing. Air source should be free of contaminates, especially oil and
water.

David Hradil et al [4] They have studied clay minerals and iron oxides are intimately related in
the process of their natural formation. Their mineralogical composition and physical properties
correspond to the physical–chemical conditions of weathering, sedimentation and alteration
 Automation For Spray Painting

processes by means of which these minerals are associated giving different types of laterites,
ferrolites, ochres, and coloured clays and soils. Very early in human history, these and other
clay materials were adopted as mineral pigments. Their structural and mineralogical features are
directly related with their natural genesis and provenance and help us in the study of historical
painting techniques and materials. This paper gives general information about geological sources
and their characteristics, the literary evidence of use of different forms of earthy pigments on
historical paintings, about analytical methods suitable in their identification within the ground
and colour layers of the painting, and handling with the samples of works of art. The examples
focused preferentially on the period of European mediaeval and baroque painting. Clayey
painting materials, particularly extenders, priming coats and many earthy pigments are important
components of the ground and colour layers of historical paintings. Their characterization,
however, is underestimated in the examination of the colour layer. The present systematic
knowledge on mineral deposits and weathering crusts and the state of art of mineralogy of clays
and other micro particulate minerals offer a new challenge to focus on the detailed evaluation of
the clayey pigments in materials research of art works.

Allan Rodrigues [5] He summarizes current trends in instrumental colour styling, colour
matching and production shading of paint and factors essential to success, with particular
emphasis on automotive finishes and research within ASTM and Detroit Colour Council
committees. Use of identical flake in standard and batch may not provide the same flop, sparkle
or texture if rheology or solids content of two paints differ. These factors affect the orientation of
the flake as the paint dries, resulting in a different apparent texture and sparkle. For automotive
colour matching requried diffuse colour matching requires only absorption and scattering
coefficients to predict reflectance. Ambient temperature are required for drying and in controlled
conditions.

United States Department of the Interior Bureau of Reclamation [6] This article gives
knowledge about heat transfer rate by using various colour. Considerable misunderstanding
exists regarding the cooling effect that can be obtained by painting transformers with different
types and colours of paint. It is thought by some that, as aluminum paint is a good reflector, that
 Automation For Spray Painting

transformers painted with aluminum will operate considerably cooler than those painted with
gray or black paint. This is true only for sources of heat outside the transformer and overlooks
the fact that heat inside the transformer must be dissipated. Heat is dissipated from the
transformer by conduction, radiation, and convection.

Berardo Naticchia et al [7] They have shared that construction projects are getting bigger
and more complex, hence also the productivity of the construction industry must be improved,
while preserving its labour from hazardous job sites. Such requirements can be accomplished by
the adoption of robotized products, which, however, need to be quickly developed and marketed.
In this paper, first the issue of a new miniature laboratory for developing lightweight and well-
coordinated robotized systems is pursued, then a novel robot device for high quality multi-colour
interior wall painting carried by a robot arm is developed and successfully tested. Thanks to
the new 1:6 scaled down laboratory and its six degree of freedom robot arm on an hexapod for
horizontal moves, we tested the opportunity to introduce also in the building sector miniature
robots that can change the ergonomics standardly adopted by construction workers. It is analyzed
how and why switching from full size to miniature robots is convenient in construction. In
addition, a new system adding further features to robotized painting has been conceived. Our
new multi-colour spraying end-tool was developed and fixed on the robot arm, in order to be
able to reproduce coloured artworks. Finally, a methodology to reproduce colours from digital
format of artworks is presented.

Dr. Sapna Johnson et al [8] They had studied lead is a highly toxic metal found in small
amounts in the earth’s crust. Because of its abundance, low cost, and physical properties, lead
and lead compounds have been used in a wide variety of products including paint, ceramics,
pipes, gasoline, batteries, and cosmetics. In India, as in most developing countries the battery
industry is the principle consumer of lead using an estimated 76% of the total primary and
secondary lead produced annually. Lead is taken up by humans by ingestion and inhalation.
Eating lead bearing paints by children and drinking of lead contaminated water are important
sources of non-industrial poisoning. Lead absorbed in course of occupational exposure is
superimposed on lead absorbed from other means which leads to increased body burden of lead.
Lead-based paints have disappeared from consumer sales for residential use in developed
countries because of toxicity concerns. However, paint containing lead is still being used for
 Automation For Spray Painting

certain industrial painting requirements. Lead is added to paint to speed drying, increase
durability, retain a fresh appearance, and resist moisture that causes corrosion.

Robert Grisso et al [9] They had done sheet covers nozzle description, recommended use for
common nozzle types, and orifice sizing for agricultural and turf sprayers. Proper selection of a
nozzle type and size is essential for correct and accurate pesticide application. The nozzle is a
major factor in determining the amount of spray applied to an area, uniformity of application,
coverage obtained on the target surface, and amount of potential drift. In spraying systems,
nozzles break the liquid into droplets and form the spray pattern. Nozzles determine the
application volume at a given operating pressure, travel speed, and spacing. Selecting nozzles
that produce the largest droplet size, while providing adequate coverage at the intended
application rate and pressure, can minimize drift. A skilled worker is required for medium scale
paint application.

Workplace Health and Safety Bulletine In industry, the most popular method of applying
paint and coatings is to spray it on using an airless sprayer, compressed air, or an electrostatic
applicator. Primers and lacquers are also commonly applied this way. When these products are
sprayed on, mists and vapours are generated which can increase your exposure to the paints or
coatings. This guide outlines some of the hazards associated with spray application and provides
information on how to protect the workers. For the safety measures over exposure of paint, too
much breathed in, absorbed by skin and making causes of diseases and irritation. Another
disadvantages of spray paints application is the combustible and flammable vapours, mists and
residues that may be created. The cost for removing all potential sources of ignition prior to
spraying flammable and combustible products is too high.
 Automation For Spray Painting

Experimental Validation
After manufacturing of our project it will looking something like this drawing, during
manufacturing if we find some useful changes to be done we will be implementing that changes.

Working of our project is explained as above :

1. Our project will be containing 2 degree of motion .
A. Horizontal motion along X-axis .
B. Vertical motion along Y-axis.
2. For this motion we will be using the dc motor , which will be working on input source of
12 volt & its torque transmitting capacity of 10 kg-cm.
3. Sprayer pump used will be working on compressed air , it will be containing the paint
reservoir for painting.
 Automation For Spray Painting

Construction

This automatic wall painting robot is not designed using complicated components. This robot is
simple and portable. The robot is designed using few steels, conveyor shaft, spray gun and a
controller unit to control the entire operation of the robot. This robot is compact because of high
speed and pressure capabilities they have. They also have a very small weight to power output
ratio and predictable performance ie., losses are minimum due to less number of moving parts
and so gives expected performance. Due to elegant and simple control systems it can control
noise vibration and does silent operation and no vibration is produced. It has longer life,
flexibility and it is efficient and dependable, and the installation is simple and the maintenance
is also easy. Some of the conditions that have to be considered while using this robot is that the
system is operates in pneumatics, so it needs air tank or compressor and the electric shock is
always there, which makes the machines ugly and dust and dirt are adhering to them. The life of
the parts like seals, packing and gaskets etc., are very short but, they are essential to prevent
leakage so that the system becomes costlier.
 Automation For Spray Painting

The construction of the automatic wall painting robot consists of two main parts. They are

1. Mobile platform

 Frame stand
 Wheel
 DC motor
 Battery
 Control unit

2. Spray gun mount

 Solenoid valve
 Flow Control Valve
 Automation For Spray Painting

Parts Specification

Robot movement will be containing following parts

1. DC motors Qty. Triple axis for double Axis movement.

2. First Degree of movement will Be on guide track.
3. The length of guide track will be approx. 1000-1200 mm.
4. Also the next axis of movement will having guide track so as to avoid the vibration and
get smooth working in up and down Direction.
5. Its Height of working will be Approx. 1000 mm .
6. Third Axis of move movement will be having guide ways but its motion of travel will be
along short distance which can be set to around 200-300mm
7. Its distance is short because its on given to set the thickness of paint which we will be
applying on the component.
8. The other parts which we will be using in our project are
9. Limit Switch it will be Used if there is requirement for automation and also if we want to
automatically stop the travel of robot if it is exceeding its limit.
10. In our project we will be able to paint all types of paint but it will be not possible for use
too by new spray gun for each and every colour so here we will be using Oil paint or
normal primer paint for painting.
11. Our complete project will be remote operated.
12. For making it remote operated we will be using rocker switches for forward and
backward motion.
13. Also for spraying we will be using Electromagnetic switches will be spring paint from
nozzle.
14. Paint reservoir will be made of capacity around 0.5-1.5 litre paint storage capacity.
15. Also we will be requiring compressed air for spray painting.
 Automation For Spray Painting

System Design
The setup consists of a long steel railing with two longitudinal grooves. Two wheels, each with a
high load capacity and cut with a circular groove along its lateral surface, are balanced on the
central limb of the railing that runs along its length between the grooves. The wheel grooves are
fit to the limb of the railing. One wheel is followed by the other along the railing. An aluminum
container houses both the wheels. These are connected to DC motors that control the movements
of wheels and lead screw. On one end of the aluminum container, a lead screw is fixed. The lead
screw extends from the top of the painting area to the very bottom. The painting arrangement is
set up in such a way that it could move up and down the lead screw. The painting setup consists
of a spray gun, a gripper, a DC motor and an IR sensor. The IR Sensor check if the area being
painted is wall or not. The actual painting is carried out by spray gun. Gripper is used as a
controlling mechanism to control the spray gun, thus regulating the flow of painting fluid. The
DC motor controls the gripper. The signals from IR sensor controls the motor, and hence the
gripper. The operation of the robot involves two endeavors, movement of the robot and painting.

They are explained in detail as follows:

 Automation For Spray Painting

Horizontal and Vertical movements

For painting the whole plane of a wall, the painting arrangement has to move in both
horizontal and vertical directions. This robot moves in horizontal direction with the help of the
wheels on the railing. The initial movement of the robot is just horizontal, painting along in a
horizontal strip. Once it reaches the end of the horizontal range of the wall, an arrangement in the
aluminum container senses by IR Sensor at the railing's end. This signals the end of the
horizontal movement. The DC motor that moves the wheels along the railing stops operation for
some time, which was fed to it as delay before the operation starts. The DC motor that is placed
in the aluminum container and controls the vertical movements now rotates the lead screw so
that the painting arrangement moves down by a step. Once the painting arrangement reaches the
next step of vertical movement, the lead screw stops rotating, and the wheels are made to move
in the reverse direction now, thus carrying out the horizontal painting in the reverse direction.
The whole plane of the wall is painted thus in a zigzag manner.

DC motors control the movement of the wheels

DC motors are, in turn, controlled by a Microcontroller. The rotation of lead screw is
controlled by a geared dc motor. The roller that rotates this screw based on the control signals
from DC motor is placed inside the aluminum container. IR Sensors on the end of the railing
determine
when to stop the horizontal movement and commence the vertical movement through the
screw. They do not commend the horizontal movement again, or stop the vertical movement.
Those two operations occur simultaneously after a preordained delay.
 Automation For Spray Painting

Painting Mechanism
The painting setup attached is attached to the lead screw. It moves vertically down based
on the lead screw rotation. The painting of the spray gun is determined by the signal from the IR
sensor. A gripper is attached to the spray gun. The pressing of this gripper causes the spray gun
to eject paint. A motor is used to press the gripper and release it based on microcontroller signal.
The IR sensor is positioned in such a way to sense any changes in the painted material even
before painting is done on a particular point in the plane. The IR sensor is attached to the
painting setup such that it moves ahead of the spray gun to determine the nature of the area being
painted. If it finds any difference in the nature of the painted area, it sends a block signal to the
microcontroller. The microcontroller actuates the motor controlling the gripper, and hence brings
about the cessation of spraying until the sensor detects the surface of the wall again. Painting
recommences when the paintable area is detected again
 Automation For Spray Painting

Calculation
The moving arrangement weight is approximately 13kg, and the painting arrangement weighs a
maximum of 10kg. So the total weight to be considered is approximately 25kg. This whole
weight acts on the wheels.

Torque = mass * distance N-m (1)

Torque = 24.5 N-m (2)

Motor selection will be done of Torque transmitting capacity of 10kg cm – (100 N cm)

Guide way frame design using simply supported system method

Given Data : Circular cross section of OD 10 mm, Load capacity of 3 kg Divided between 3
guide channels.
 Automation For Spray Painting

Shear Force Diagram (SFD)

Bending Moment Diagram (BMD)

10 mm OD, guide is safe & can used in our system.

 Automation For Spray Painting

Conclusions
The fabrication of painting robot based on the specifications explained above is currently
in progress. The method proposed here applies only for buildings with flat wall surfaces. If
buildings of complex shapes were to use this method, complicated railing shapes should be
called to play. The robot does commendable help in avoiding the risk factor involved in manual
painting with high altitudes. It also helps to overcome the health problems in painting like
irritation of eye and skin. The robot has been designed in a cost effective and time effective
manner.
For small and medium scale industries manufacturing components have to coat or paint
to prevent from rusting so the spray application consumes more time and paint as well as with
the skilled worker evolved with the application. They cannot afford robotic arrangement for
higher accuracy so the rise of the such process have to be made which is economical, gives better
accuracy, consumes less time for coating so project aim has to developed such mechanism which
coat the components with the dipping process having semi-automatic arrangement which is
suitable for our requirement and which can be beneficial for small and medium scale industries.
 Automation For Spray Painting

Future Scope

1. Automation using electrical sensors.

2. Maximum area to be covered for painting.
 Automation For Spray Painting

References

[1] Seth Berrier, Gary Meyer, Clement Shimizu, ―A Computer Graphics System for Examining
Paint Color Collections‖ , Department of Computer Science & Engineering, University of
Minnesota, USA

[2] Published by Nordson Corporation, ―Airless Spray Systems‖ , 2004.

[3] Application Guide, ―Auto Air Colour‖ , Dec. 2008.

[4] David Hradil , Toma´s Grygar, Janka Hradilova, Petr Bezdicˇka, ―Clay and iron oxide
pigments in the history of painting‖ , Jan. 2003.

[5] Allan RODRIGUES DuPont Performance Coatings, ―Colour technology and paint‖, Colour
and Paints, Interim Meeting of the International Colour Association, 2004

[6] United States Department of the Interior Bureau of Reclamation, ―Painting of Transformers
and circuit Breakers‖ November 1991.
[7] Berardo Naticchia, Alberto Giretti and Alessandro Carbonari, ―Set Up of an Automated
Multi-Colour System for Interior Wall Painting, Advanced Robotic System.

[8] Dr. Sapna Johnson, Dr. Nirmali Saikia, Mr. Ramakant Sahu, ―Lead in Paints‖ , Pollution
Monitoring Laboratory India Habitat Center, Core-6a, New Delhi, 2009.

[9] Robert Grisso, Pat Hipkins, David Mccall, Shawn D. Askew, Lloyd Hipkins, ―Nozzles:
Selection and Sizing‖ , Virginia State University.

[10] Workplace Health and Safety Bulletine, ―Spray Application of Paint and Coatings‖ .