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Research and realization of assistant off-line programming system for thermal spraying

Abstract : The offline programming technology provides the possibility to generate complex robot trajectories in thermal spray process. In the laboratory of LERMPS, an add-in software called “Thermal SprayToolkit” (T.S.T.) has been developed to assist the offline programming in the field of thermal spray.However, efforts are still expected to improve the functionality of this software. The aim of this study is to improve the application of offline programming technology in the thermal spray process. According to the procedure of the offline programming in thermal spray, the work of this thesis consists of three parts.Firstly, efforts have been dedicated to improve the module “PathKit” in T.S.T., which aim to improve the functionality of trajectory generation. The algorithm of trajectory generation for the curved substrate surface was improved to maintain a constant scan step. A novel Archimedean spiral trajectory was developed for damage component recovery application by cold spray. The experiment of an Al5056 coating depositing on a manually manufactured workpiece with a crater defect was carried out to validate the effects of spiral trajectory with adapted nozzle speed.Secondly, numerical models were developed to simulate the coating thickness distribution in 2D and 3D, and then integrated in the RobotStudio™ as an individual module named “ProfileKit”. In the “ProfileKit 2D”, it is able to evaluate the effects of operating parameters on coating profile and optimize the parameters. In the “ProfileKit 3D”, coating thickness distribution can be simulated based on the nozzle trajectory and robot kinematics data. The functionalities were validated by the trapezoid coldsprayed coating.At last, kinematic analysis was used to provide the optimization methods for a better robot performance in thermal spraying. In order to better evaluate the robot performance, an overall parameter (OP) that is the weighted mean of standard deviation of joint speed, was introduced to measure the complexity of a robot trajectory. Afterwards, the optimal nozzle mounting method as well as the optimal workpiece placement were investigated by the kinematic analysis and the overall parameter. The result shows that the kinematic optimization can effectively improve the robot performance to maintain the predefined speed.
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Submitted on : Tuesday, September 11, 2018 - 3:19:27 PM
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  • HAL Id : tel-01872036, version 1



Chaoyue Chen. Research and realization of assistant off-line programming system for thermal spraying. Automatic. Université de Technologie de Belfort-Montbeliard, 2016. English. ⟨NNT : 2016BELF0303⟩. ⟨tel-01872036⟩



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