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Six-axis Manipulator

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Advantages of Industrial Robots & Features of Six-Axis Manipulators for Spraying

Industrial robots enhance coating processing efficiency and cut coating costs. Compared with traditional single-axis or two-axis manipulators, programmed six-axis manipulators deliver higher spraying efficiency—they reduce coating dispersion and significantly save consumables. Robotic arms are computer-controlled; spraying sections can be pre-programmed for precise control, boosting spraying efficiency, minimizing over-spraying, and avoiding waste.

Spraying industrial robots improve workpiece coating quality. They enable multi-angle spraying coverage and adjustable spraying distances. For different workpieces, materials, and required coating thicknesses, parameters like spraying distance, dwell time, and angle can be adjusted via the robot to achieve high-quality coatings.

Imported six-axis manipulators, widely used in the thermal spraying industry, enjoy a strong reputation for stable performance and can handle spray guns weighing up to 25 kg.

Manipulator Features

High-strength arms and top-tier six-axis servo technology effectively enhance the speed and acceleration/deceleration performance of each axis. Movement time is reduced by over 15%, achieving industry-leading productivity.
The wrist axis adopts an independent drive mechanism, creating an ultra-compact robotic arm with built-in cables—one of the most refined designs globally. This enables stable robot operation in narrow spaces and high-density work environments.
The front cantilever offers excellent cable integration, ensuring smooth cable routing for easier maintenance. Optional hand cable inserts are also available.
Stable hand cable management lowers the teaching cost of offline programming. Enhanced wrist load capacity supports various processing devices, including sensor units, dual grippers, and multi-functional composite grippers.
The manipulator’s front end is modified with an added gun holder, allowing quick spray gun installation.
A seventh axis is integrated to enable spraying of long-axis workpieces.

Application Scenarios & Operation Guide for Six-Axis Manipulators (Thermal Spraying)

I. Application Scenarios

1. Metal Part Repair

In industries like machinery manufacturing, automotive, and aerospace, many metal parts suffer from wear and corrosion after long-term use. The Six-axis manipulator enables precise control of the thermal spray gun, spraying a metal coating onto the worn areas. This restores the parts’ original dimensions and performance, extends their service life, and reduces equipment maintenance costs.

2. Surface Strengthening Treatment

For parts requiring enhanced surface hardness, wear resistance, and corrosion resistance—such as molds and mechanical shafts—the six-axis manipulator can evenly spray wear-resistant and corrosion-resistant coating materials onto the workpiece surface. This boosts the parts’ surface properties, improving their reliability and stability in harsh working environments.

3. New Coating Material R&D

The development of new thermal spray coating materials requires spraying experiments with materials of different formulations to evaluate their performance and applicability. The six-axis manipulator can accurately spray new coating materials onto various substrates according to experimental requirements, providing reliable data support for material research and development.

II. Product Operation Guide

1. Pre-Startup Preparation

Ensure the work area is clean and free of debris, with ambient temperature and humidity within the specified range (0–40°C, 20%–80%).
Inspect the manipulator’s mechanical structure, connecting components, and cables for damage or looseness; prepare the required end effector and spraying materials.

2. Power-On & Initialization

Turn on the power supply, observe the indicator lights, and check for any self-test abnormalities (e.g., error codes, warning lights).
Wait for the robotic arm to automatically return to its home position; confirm the system displays “Initialization Completed” before proceeding.

3. Manual Operation Mode

Switch the system to “Manual” mode, then use the control panel buttons to manipulate the robotic arm’s movement.
Press the corresponding axis buttons to control the arm’s movement along the X and Y axes. Practice operation at low speed first to familiarize yourself with the controls, and adjust the arm to a position close to the material.
Use the dedicated buttons to control the end effector: test the gripper’s opening/closing action and gripping force to ensure normal functionality.

4. Automatic Programming & Teaching Operation

Toggle the system to “Programming” mode to activate the teaching function; connect the teach pendant or use the touchscreen for operation.
Hold the teach pendant to manually guide the robotic arm through the required process path. Set parameters for each key point (e.g., position, speed) and spray gun (e.g., spray pressure, flow rate), then record this information to generate an operation program.
Save the program and perform a test run. If abnormalities occur (e.g., incorrect positioning), adjust the parameters and re-test until the program runs smoothly.

5. Automatic Operation

Confirm the workpiece is properly positioned, the spraying materials are sufficient, and all parameters match the process requirements before starting.
Switch the system to “Auto” mode, press the “Start” button to begin operation. Monitor the manipulator’s running status in real time; if an abnormality occurs (e.g., material shortage, position deviation), press the “Stop” button immediately and troubleshoot.

6. Parameter Adjustment

Adjust the robotic arm’s motion parameters (e.g., speed, acceleration) via the control panel or supporting software. Balance speed and precision according to the task, and optimize start/stop smoothness to avoid material waste.
Adjust the end effector’s parameters based on the specific task: ensure the gripper can hold materials stably, and fine-tune the spray gun’s working parameters (e.g., spray angle, distance) for optimal coating quality.

7. Shutdown Process

After the task is completed, control the robotic arm to return to its home position and reset the end effector to its standby state.
Switch the system back to “Manual” mode, then turn off the control system and main power supply in sequence. Clean the equipment (e.g., wipe the arm surface, clean the spray gun nozzle) to prepare for the next use.

FAQ About Manipulator Installation, Accuracy Maintenance & Equipment Linkage

Q: Do you need special site conditions for the installation of the manipulator?

A: Yes, specific site conditions are recommended. The manipulator should be installed in a dry, well-ventilated indoor environment free from strong vibration. The ground must have sufficient load-bearing capacity to place the equipment stably. Additionally, the operating temperature should be within the range of 0–40°C; temperatures outside this range may impair the performance of electronic components and the stability of the mechanical structure—for example, high temperatures can trigger overheating protection for motors, while low temperatures increase the viscosity of lubricating oil and reduce transmission efficiency.

Q: How can I maintain high accuracy over a long period of time?

A: Long-term high accuracy relies on regular and standardized maintenance:

Clean the dust and oil on the manipulator’s surface at specified intervals to prevent them from entering the mechanical structure and affecting accuracy.
Inspect and tighten all connecting parts regularly to avoid loosening caused by long-term operation.
Lubricate transmission components (such as lead screws and guide rails) on a fixed schedule to reduce wear.
Recalibrate accuracy at certain production batch intervals or cycles.
Monitor ambient temperature and humidity in real time, and adjust process parameters promptly to adapt to environmental changes—all of which ensure high-precision operation.

Q: Can other existing automation equipment of the company be linked with a six-axis robot?

A: Yes, it can. The six-axis manipulator is equipped with multiple communication interfaces (e.g., RS485, Ethernet). As long as your existing automation equipment has matching communication capabilities, data interaction and linkage control can be achieved by writing appropriate communication protocols. This allows collaborative completion of complex production tasks—for instance, cooperating with PLCs to control the automated process of production lines, or working with other industrial robots to handle large workpiece processing.

Product Introduction

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FAQ