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Compact Mechanical Arm Centralized Control System

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Advantages of Industrial Robots and Key Features of Six-Axis Manipulators for Spraying Applications

Industrial robots bring significant value to coating processes by boosting operational efficiency and lowering overall coating costs. In comparison to conventional single-axis or dual-axis manipulators, programmed six-axis manipulators stand out for their superior spraying efficiency: they minimize coating material dispersion and substantially reduce consumable waste. Controlled by computer systems, these robotic arms allow pre-programming of specific spraying sections, ensuring precise process control. This precision not only enhances spraying efficiency but also curbs over-spraying, thereby eliminating unnecessary material waste.

Industrial spraying robots also play a critical role in elevating workpiece coating quality. They enable multi-angle spraying coverage and offer adjustable spraying distances—two key factors in achieving uniform, high-quality finishes. For varying workpiece types, coating materials, and required film thicknesses, parameters such as spraying distance, dwell time, and spray angle can be fine-tuned directly via the robot’s control system, ensuring consistent results across production runs.

Key Features of Imported Six-Axis Manipulators

Widely adopted in the thermal spraying industry, imported six-axis manipulators are renowned for their reliable performance and can accommodate spray guns weighing up to 25 kg. Their core features include:

Enhanced Speed and Productivity
Equipped with high-strength arm structures and top-tier six-axis servo technology, these manipulators deliver exceptional speed and acceleration/deceleration performance across all axes. This translates to a 15%+ reduction in movement time, enabling productivity levels that lead the industry.
Compact Design for Space Efficiency
The wrist axis utilizes an independent drive mechanism, resulting in an ultra-compact robotic arm with internally routed cables—one of the most sophisticated designs available globally. This compact layout allows stable operation even in narrow workspaces or high-density production environments, maximizing floor space utilization.
Optimized Cable Management & Maintainability
The front cantilever is engineered for seamless cable integration, ensuring neat, unobstructed cable routing that simplifies maintenance tasks. Additionally, optional hand cable inserts are available to further customize and streamline cable management.
Reduced Programming Costs & Versatile Load Capacity
Stable hand cable management lowers the teaching and setup costs associated with offline programming. Moreover, the manipulator’s enhanced wrist load capacity supports a wide range of processing devices, including sensor units, dual grippers, and multi-functional composite grippers—expanding its applicability beyond basic spraying.
Quick Spray Gun Installation
The front end of the manipulator is modified with an integrated gun holder, allowing for rapid and tool-free installation of spray guns. This reduces downtime during tool changes and improves overall operational efficiency.
Long-Axis Workpiece Compatibility
A built-in seventh axis is integrated into the design, enabling the manipulator to handle spraying tasks for long-axis workpieces—addressing a common limitation of standard six-axis systems in large-part manufacturing.

Application Scenarios and Operation Guide for Six-Axis Manipulators in Thermal Spraying

I. Application Scenarios

Six-axis manipulators, with their high precision, flexibility, and stable performance, are widely applied in thermal spraying processes across multiple industries. Their core application scenarios include the following:

1. Metal Part Repair

In sectors such as machinery manufacturing, automotive, and aerospace, long-term use often causes critical metal components to suffer from wear, corrosion, or surface damage—issues that can compromise equipment performance or lead to premature replacement. Six-axis manipulators address this by enabling precision control of thermal spray guns: they accurately target worn or corroded areas, spraying a tailored metal coating to restore the part’s original dimensions, structural integrity, and functional performance. This not only extends the service life of valuable components but also significantly reduces overall equipment maintenance and replacement costs.

2. Surface Strengthening Treatment

For components requiring enhanced surface durability—such as industrial molds, mechanical shafts, and hydraulic parts—six-axis manipulators deliver uniform thermal spraying of wear-resistant, corrosion-resistant, or high-temperature-resistant coating materials (e.g., ceramic, alloy-based coatings). By ensuring consistent coating thickness and full surface coverage, the manipulator boosts the part’s surface hardness, wear resistance, and resistance to harsh environments (e.g., high humidity, chemical exposure). 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. Six-axis manipulators serve as a critical tool in this R&D process: they can be programmed to spray new coating materials onto various test substrates (e.g., steel, aluminum, titanium) with precise control over parameters like coating thickness, spray pressure, and dwell time. This consistency in testing ensures reliable, reproducible data—supporting researchers in evaluating material performance, optimizing formulations, and validating the applicability of new coatings for industrial use.

II. Operation Guide for Six-Axis Manipulators (Thermal Spraying)

To ensure safe, efficient, and high-quality thermal spraying operations, follow this step-by-step guide:

1. Pre-Startup Preparation

Work Area Check: Ensure the operation area is clean, free of debris, flammable materials, or obstacles that could interfere with the manipulator’s movement. Verify that ambient conditions (temperature: 0–40°C; relative humidity: 20%–80%) meet the equipment’s specified requirements.
Equipment Inspection: Examine the manipulator’s mechanical structure (arms, joints), connecting components (fasteners, hinges), and cables (power, signal, pneumatic) for signs of damage, wear, or looseness. Replace or tighten any defective parts.
Tool & Material Prep: Prepare the required end effector (e.g., thermal spray gun, gripper) and ensure it is properly calibrated. Confirm that thermal spraying materials (powders, wires) are sufficient, stored correctly, and compatible with the task.

2. Power-On & Initialization

Turn on the main power supply and the manipulator’s control system. Observe the indicator lights on the control panel; if any error codes, warning lights, or abnormal sounds appear, stop the process immediately and troubleshoot (refer to the equipment manual for error resolution).
Wait for the manipulator to complete its automatic homing sequence—this resets the arm to its default starting position. Only proceed when the control system displays “Initialization Completed” (or a similar confirmation message).

3. Manual Operation Mode

Manual mode is intended for setup, calibration, or minor adjustments (never use manual mode during full production runs).

Switch the control system to “Manual” mode (often via a physical switch or touchscreen option). Use the control panel buttons or a handheld jog pendant to manipulate the manipulator’s movement.
Control the arm’s motion along the X/Y/Z axes and rotational axes by pressing the corresponding buttons. Start with low-speed operation to familiarize yourself with the controls, then adjust the arm to a position close to the workpiece (ensure no collision risk).
Test the end effector: Activate the spray gun’s trigger (without material flow, if possible) to check for smooth operation, and verify the gripper’s opening/closing action and gripping force (adjust if necessary to avoid damaging workpieces).

4. Automatic Programming & Teaching Operation

Programming (or “teaching”) defines the manipulator’s path and spraying parameters for automatic runs.

Switch the system to “Programming” mode and connect the teach pendant (if required) or use the control system’s touchscreen interface.
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), set parameters such as:

Motion parameters: Speed, acceleration, 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., “Mold_Surface_Spray_01”) for easy identification.
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 full-scale production after programming is finalized.

Confirm pre-operation checks: Ensure the workpiece is securely positioned on the fixture, spraying materials are loaded and primed, and all parameters match the process requirements (cross-verify with the program).
Switch the 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 path, 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.

6. Parameter Adjustment

Parameters may need optimization based on workpiece type, coating requirements, or material changes.

Adjust motion parameters (speed, acceleration) via the control panel or supporting software: Balance speed (for efficiency) and precision (for coating quality)—avoid excessive speed, which can cause over-spraying or uneven coverage. Optimize start/stop smoothness to prevent material waste at path transitions.
Fine-tune end effector parameters: For the spray gun, adjust the spray angle (typically 45°–90° for optimal coverage) and distance (usually 10–20 cm, depending on the material). For the gripper, adjust gripping force to match the workpiece’s weight and fragility.

7. Shutdown Process

Proper shutdown protects equipment and ensures readiness for the next use.

After the task is completed, use the control system to send the manipulator back to its home position. 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 manipulator’s arm surface to remove dust or residual material; clean the spray gun nozzle (using a compatible solvent) to prevent clogging; and dispose of waste materials (e.g., empty material containers) according to safety regulations.
Record operation logs (e.g., program used, runtime, issues encountered) for future reference and maintenance planning.

FAQ: Manipulator Installation, Accuracy Maintenance, and Equipment Linkage

Q1: Are special on-site conditions required for manipulator installation?

A: Yes, specific on-site conditions are necessary to ensure the manipulator operates stably and safely long-term. The key requirements include:

Environmental conditions: Install the manipulator in a dry, well-ventilated indoor space free from strong vibrations (e.g., avoid areas near heavy machinery with high oscillation). This prevents dust, moisture, or vibration from damaging internal components.
Ground load-bearing capacity: The installation floor must have sufficient load-bearing capacity to support the manipulator’s weight (including end effectors like spray guns) and ensure stable placement—uneven or weak ground can cause misalignment over time.
Temperature range: Maintain an operating temperature between 0–40°C. Temperatures outside this range risk impairing performance:

High temperatures may trigger overheating protection in motors, leading to unexpected shutdowns.
Low temperatures increase the viscosity of lubricating oils, reducing the efficiency of mechanical transmission (e.g., slower axis movement, increased wear).

Q2: How to maintain high operational accuracy of the manipulator over the long term?

A: Sustained high accuracy depends on regular, standardized maintenance and environmental control. Follow these key steps:

Routine surface cleaning: At scheduled intervals (e.g., daily or weekly, depending on usage intensity), clean dust, oil, or residual coating material from the manipulator’s surface. This prevents contaminants from entering gaps in the mechanical structure (e.g., joints, guide rails) and causing friction or misalignment.
Tighten connecting components: Regularly inspect and re-tighten bolts, screws, and other fasteners (e.g., monthly). Long-term operation and vibration can loosen these parts, directly affecting positional accuracy.
Scheduled lubrication: Lubricate critical transmission components (e.g., lead screws, guide rails, rotating joints) at fixed intervals (per the equipment manual). High-quality lubricant reduces metal-to-metal wear and ensures smooth, precise movement.
Periodic accuracy recalibration: Recalibrate the manipulator’s accuracy after a set number of production batches or operating cycles (e.g., every 3–6 months). Use professional calibration tools (e.g., laser trackers) to adjust axis positioning and restore precision if deviations are detected.
Real-time environmental monitoring: Track ambient temperature and humidity. If conditions fluctuate beyond the recommended range (0–40°C, 20%–80% humidity), adjust process parameters (e.g., reduce motor load in high temperatures) to minimize accuracy loss.

Q3: Can the six-axis manipulator be linked with the company’s existing automation equipment?

A: Yes, six-axis manipulators are designed for compatibility with most existing automation systems, enabling seamless linkage. Here’s how it works:

Built-in communication interfaces: Six-axis manipulators typically come with multiple standard interfaces, such as RS485 (for short-distance data transmission) and Ethernet (for high-speed, long-distance communication).
Protocol matching: As long as your existing automation equipment (e.g., PLCs, conveyor systems, other industrial robots) supports compatible communication protocols (e.g., Modbus, Profinet), you can achieve data interaction and coordinated control by programming the appropriate protocols.
Practical applications: This linkage allows the manipulator to collaborate with other equipment to complete complex tasks—for example:

Working with a PLC to automate a full coating line (e.g., the PLC triggers the manipulator to start spraying once a workpiece is positioned by the conveyor).
Cooperating with other robots to handle large or irregular workpieces (e.g., one robot positions the workpiece, while the six-axis manipulator performs precision spraying).

Product Introduction

Product Uses

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FAQ