Application Scenarios & Operation Guide for Zhengzhou Lijia’s Two-Axis Manipulator (Thermal Spraying)
I. Core Application Scenarios
Zhengzhou Lijia’s two-axis manipulator, with its high precision and stable performance, is widely applicable to thermal spraying tasks across machinery, automotive, aerospace, and R&D fields. Its key application scenarios are as follows:
1. Metal Part Repair
In industries such as machinery manufacturing, automotive, and aerospace, long-term operation causes critical metal components (e.g., engine parts, transmission shafts, aircraft structural components) to suffer from wear, corrosion, or surface damage—issues that degrade performance or force premature replacement. The two-axis manipulator addresses this by enabling precision control of thermal spray guns: it accurately targets worn or corroded areas, spraying customized metal coatings (e.g., alloy, ceramic-based coatings) to restore the part’s original dimensions, structural integrity, and functional performance. This not only extends the service life of high-value components but also significantly reduces equipment maintenance and replacement costs for enterprises.
2. Surface Strengthening Treatment
For components requiring enhanced surface durability—such as industrial molds (injection molds, stamping molds), mechanical shafts (gear shafts, hydraulic shafts), and high-load parts—the two-axis manipulator delivers uniform thermal spraying of wear-resistant, corrosion-resistant, or high-temperature-resistant coating materials. Leveraging its ±0.05mm–±0.1mm repeat positioning accuracy, the manipulator ensures consistent coating thickness and full surface coverage, effectively boosting the part’s surface hardness, wear resistance, and resistance to harsh environments (e.g., high humidity, chemical erosion, repeated friction). This improves the component’s reliability, reduces failure rates, and extends its operational lifespan in demanding working conditions.
3. New Coating Material R&D
The development of advanced thermal spray coating materials relies on rigorous testing of formulations, adhesion, and performance across different substrates. The two-axis manipulator serves as a critical tool in this R&D process: it can be programmed to spray new coating materials (with varying compositions or particle sizes) onto diverse test substrates (e.g., steel, aluminum, titanium) with precise control over parameters like coating thickness, spray pressure, and dwell time. Its stable and repeatable operation ensures reliable, reproducible experimental data—supporting researchers in evaluating material performance, optimizing formulations, and validating the applicability of new coatings for industrial-scale use.
II. Detailed Operation Guide for the Two-Axis Manipulator
To ensure safe, efficient, and high-quality thermal spraying operations, follow this step-by-step guide (aligned with the manipulator’s intelligent control system and structural features):
1. Pre-Startup Preparation
Before powering on the equipment, complete the following checks to eliminate safety hazards and ensure stable operation:
Work Area Inspection: Ensure the operation area is clean, free of debris, flammable materials, or obstacles that could interfere with the manipulator’s X/Y-axis movement. Verify that ambient conditions meet the specified requirements: temperature (0–40°C) and relative humidity (20%–80%).
Equipment & Component Check: Examine the manipulator’s mechanical structure (X/Y-axis rails, connecting joints), fasteners (bolts, screws), and cables (power, signal, pneumatic) for signs of damage, wear, or looseness. Replace defective parts or tighten loose connections promptly.
Tool & Material Preparation: Install the required end effector (e.g., thermal spray gun, pneumatic gripper) via the standardized interface, and confirm it is properly calibrated. Prepare sufficient thermal spraying materials (powders or wires) and ensure they are compatible with the task and stored in a dry environment.
2. Power-On & Initialization
Turn on the main power supply and the manipulator’s control system. Observe the indicator lights on the touch screen or control panel; if error codes, warning lights, or abnormal sounds appear, stop the process immediately and refer to the equipment manual for troubleshooting (e.g., checking cable connections or power stability).
Wait for the manipulator to complete its automatic homing sequence—this resets the X/Y axes to their default starting positions. Only proceed with subsequent operations when the control system displays “Initialization Completed” (or a similar confirmation prompt).
3. Manual Operation Mode
Manual mode is intended for setup, calibration, or minor position adjustments (do not use manual mode during formal production):
Switch the control system to “Manual” mode (via the touch screen or physical switch). Use the control panel buttons or a handheld teach pendant to manipulate the manipulator’s X/Y-axis movement.
Press the X-axis/Y-axis direction buttons to control the arm’s linear motion. Start with low-speed operation (e.g., 0.2m/s) to familiarize yourself with the control sensitivity, then adjust the manipulator to a position close to the workpiece (ensure no collision risk with fixtures or other equipment).
Test the end effector: Activate the spray gun’s trigger (without material flow, if possible) to check for smooth operation, or test the pneumatic gripper’s opening/closing action and gripping force—adjust the force if necessary to avoid damaging workpieces.
4. Automatic Programming & Teaching Operation
Programming (teaching) defines the manipulator’s spraying path and parameters for automatic production runs, leveraging the system’s “teaching and reproduction” function:
Switch the control system to “Programming” mode. Connect the teach pendant (if used) or directly operate via the user-friendly touch screen.
Use the teach pendant to manually guide the manipulator along the desired spraying path. At key points (e.g., start/end of a spray pass, corners of the workpiece), set critical parameters via the touch screen:
Motion parameters: X/Y-axis speed (up to 1–2m/s, adjusted based on precision needs), acceleration, and dwell time at each point.
Spraying parameters: Spray pressure, material flow rate, spray angle, and distance from the workpiece.
Save each key point and parameter to generate a complete operation program. Name the program clearly (e.g., “Shaft_Surface_Spray_01”) for easy identification in subsequent runs.
Perform a dry test run (without spraying material) to validate the program. If issues arise (e.g., incorrect positioning, uneven path), adjust the key points or parameters and retest until the program runs smoothly.
5. Automatic Operation
Automatic mode is used for formal production after programming and testing are finalized:
Confirm pre-operation checks: Ensure the workpiece is securely fixed on the fixture, spraying materials are loaded and primed, and all parameters (motion, spraying) match the process requirements.
Switch the control system to “Auto” mode, then press the “Start” button (some systems require a two-hand start for safety).
Monitor the manipulator’s operation in real time: Track its X/Y-axis movement, spray coverage, and material flow. If abnormalities occur (e.g., material shortage, position deviation, unusual noises), press the emergency stop (E-stop) button immediately. Resolve the issue (e.g., refill materials, reposition the workpiece) before restarting the program.
6. Parameter Adjustment
Based on workpiece type, coating requirements, or production efficiency needs, optimize parameters via the control panel or touch screen:
Motion Parameter Adjustment: Modify X/Y-axis speed and acceleration to balance efficiency and precision. For fine spraying tasks (e.g., small workpieces), reduce speed to ±0.5m/s to ensure accuracy; for large-area spraying, increase speed (up to 2m/s) to improve efficiency. Optimize start/stop smoothness to prevent over-spraying or material waste at path transitions.
End Effector & Spraying Parameter Adjustment: Adjust the spray gun’s angle (typically 45°–90° for uniform coverage) and distance (10–20cm, based on material type). For the gripper, adjust gripping force to match the workpiece’s weight and fragility—ensure stable clamping without deformation.
7. Shutdown Process
Proper shutdown protects the manipulator’s precision components and ensures readiness for the next use:
After the task is completed, use the control system’s “Return to Origin” function to move the X/Y axes back to their home positions. Reset the end effector to standby (e.g., retract the spray gun, open the gripper).
Switch the system from “Auto” to “Manual” mode, then turn off the control system and main power supply in sequence.
Perform post-operation cleaning: Wipe down the X/Y-axis rails and manipulator surface to remove dust or residual coating material; clean the spray gun nozzle (using a compatible solvent) to prevent clogging; dispose of waste materials (e.g., empty material containers) according to safety regulations.
Record operation logs (e.g., program used, runtime, material consumption, issues encountered) to facilitate subsequent maintenance and process optimization.
