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Precise Movement: It is equipped with a high-precision servo motor and a precision reducer. The repeated positioning accuracy of the X and Y axes can reach ±0.05mm - ±0.1mm, which can ensure a uniform coating. Moreover, its response is rapid, with a maximum speed of 1 - 2m/s, enabling fast start and stop, and improving production efficiency.
Wide Adaptability: The working area of the manipulator is large, with an X-axis range of 500 - 2000mm and a Y-axis range of 300 - 1500mm, which is suitable for workpieces of various sizes. In addition, the end effector has a standardized interface, which can quickly change pneumatic grippers, vacuum suction cups, etc., to meet different production tasks.
Intelligent Control: It adopts a self-developed system, and the touch screen is easy to operate. The teaching and reproduction function can shorten the commissioning period. At the same time, it has a perfect fault diagnosis and early warning function to ensure the continuous operation of the equipment.
Stable and Durable: The main body is made of high-strength aluminum alloy, which is heat-treated, with high rigidity and low weight. The transmission parts are made of high-quality alloy steel, which is well-lubricated and wear-resistant. The strong surface protection enables it to resist harsh environments and has a long service life.
Strong R & D and Service Capabilities: The company has 127 domestic patents, 14 trademarks, 1 work copyright, and 6 software copyrights. In addition, the company also provides a considerate after-sales service. When a fault occurs, it will contact the customer within 5 minutes, give a solution within 1 hour, and the technical personnel will reach the site within 24 hours and repair the fault within 4 hours.
The equipment is composed of two parts of the two-axis manipulator and the console, the system is connected by a data line, through the manual mode and the automatic mode of the console, the manipulator can be realized to carry out reciprocating motion and equidistant movement (the plane spraying can be realized, and the turntable can be connected to realize the shaft surface spraying), the program of the manipulator is the most accessible design method in China, and the beginners can learn it in 10 minutes at the earliest, so it is widely acclaimed.
Figure Two-axis manipulator
1. The manipulator adopts all-steel plate dust cover, as our company's patented product, the manipulator is professionally designed and manufactured for the thermal spraying industry, with dustproof, heat insulation, bump resistance, strong rigidity and large load.
2. This manipulator adopts Delta servo motor, which can spray long workpieces, the X-axis is horizontal, the Y-axis is vertical, and the manipulator can automatically move to the specified position, with high positioning and repeatability.
3. The operation program of the manipulator adopts a built-in automatic program, and when operating, only a few simple parameters need to be entered, and a variety of path planning can be completed without .
4. It has the function of automatic round-trip and counting. The round-trip length can be easily set, and the counting will automatically stop when the count is in place, and it can be connected to the turntable.
5. The main electrical components adopt international brands to effectively ensure the trouble-free operation of the equipment.
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.
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).
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.
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.
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.
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.
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.
Clean the dust and oil residues on the robotic arm’s surface at scheduled intervals to prevent them from entering the mechanical structure and affecting precision.
Inspect and tighten all connecting components regularly to avoid loosening, which could lead to positional deviations.
Lubricate transmission parts (such as lead screws and guide rails) on a regular basis to minimize wear and ensure smooth movement.
Recalibrate the manipulator’s accuracy at set intervals (e.g., after a specific number of production batches or a fixed time cycle).
Monitor ambient temperature and humidity in real time, and adjust process parameters promptly to adapt to environmental changes—this helps maintain consistent high-precision operation.
Cooperating with a PLC (Programmable Logic Controller) to automate the entire production line process.
Working in tandem with industrial robots to handle large-scale workpiece processing or assembly operations.
