杰瑞斯智能涂裝機器人及噴涂工藝
一、常(chang)見的噴涂工藝有以下幾種(zhong)：
1、輥涂
輥(gun)涂(tu)(tu)是(shi)以轉(zhuan)輥(gun)作涂(tu)(tu)料(liao)的(de)(de)載體，涂(tu)(tu)料(liao)在(zai)轉(zhuan)輥(gun)表面形成一定厚度(du)的(de)(de)濕膜，然后借(jie)助轉(zhuan)輥(gun)在(zai)轉(zhuan)動過(guo)程中與被涂(tu)(tu)物(wu)(wu)(wu)接觸(chu)，將(jiang)涂(tu)(tu)料(liao)涂(tu)(tu)敷在(zai)被涂(tu)(tu)物(wu)(wu)(wu)的(de)(de)表面。輥(gun)涂(tu)(tu)適用(yong)于平(ping)面狀的(de)(de)被涂(tu)(tu)物(wu)(wu)(wu)，廣泛應用(yong)于金屬(shu)板(ban)、膠合板(ban)、布(bu)與紙的(de)(de)涂(tu)(tu)裝，特別適用(yong)于金屬(shu)卷材(cai)涂(tu)(tu)裝。
2、空氣噴涂（噴槍加壓(ya)縮空氣）
空(kong)氣(qi)噴(pen)(pen)涂(tu)(tu)是目前(qian)油漆(qi)涂(tu)(tu)裝施工(gong)中采(cai)用(yong)得比較廣泛的一種涂(tu)(tu)飾工(gong)藝。空(kong)氣(qi)噴(pen)(pen)涂(tu)(tu)是利用(yong)壓(ya)縮空(kong)氣(qi)的氣(qi)流，流過噴(pen)(pen)槍(qiang)噴(pen)(pen)嘴孔形(xing)成(cheng)負壓(ya)，負壓(ya)使(shi)漆(qi)料(liao)從吸管吸入，經(jing)噴(pen)(pen)嘴噴(pen)(pen)出，形(xing)成(cheng)漆(qi)霧(wu)，漆(qi)霧(wu)噴(pen)(pen)射到(dao)被涂(tu)(tu)飾零部件表面上形(xing)成(cheng)均勻的漆(qi)膜。
3、靜(jing)電噴涂
靜(jing)電噴(pen)涂(tu)分(fen)液體靜(jing)電噴(pen)涂(tu)，粉末靜(jing)電噴(pen)涂(tu)，其原理是利用高(gao)壓靜(jing)電電場(chang)使帶負電的涂(tu)料(liao)微(wei)粒沿著(zhu)電場(chang)相反的方(fang)向定(ding)向運動(dong)，并將涂(tu)料(liao)微(wei)粒吸附在工件表面的一(yi)種(zhong)噴(pen)涂(tu)方(fang)法。靜(jing)電噴(pen)涂(tu)設備由(you)噴(pen)槍(qiang)、噴(pen)杯以(yi)及靜(jing)電噴(pen)涂(tu)高(gao)壓電源(yuan)等(deng)組(zu)成。液體靜(jing)電噴(pen)槍(qiang)分(fen)手(shou)動(dong)水(shui)(shui)性(xing)、油(you)性(xing)靜(jing)電噴(pen)槍(qiang)，自(zi)動(dong)水(shui)(shui)性(xing)、油(you)性(xing)靜(jing)電噴(pen)槍(qiang)，水(shui)(shui)性(xing)、油(you)性(xing)自(zi)動(dong)靜(jing)電旋杯霧化器等(deng)，供漆系統(tong)(tong)一(yi)般分(fen)低壓涂(tu)料(liao)輸送(song)壓力桶或者隔(ge)膜泵(beng)，高(gao)壓柱塞泵(beng)供漆系統(tong)(tong)，涂(tu)料(liao)自(zi)動(dong)配比(bi)混合(he)系統(tong)(tong)，自(zi)動(dong)換色控(kong)制系統(tong)(tong)，杯頭自(zi)動(dong)清洗控(kong)制系統(tong)(tong)，精(jing)密流(liu)量(liang)閉環控(kong)制系統(tong)(tong)，齒輪泵(beng)精(jing)密流(liu)量(liang)控(kong)制系統(tong)(tong)等(deng)噴(pen)涂(tu)。
4、電(dian)泳(yong)噴涂
電泳涂(tu)裝(zhuang)(electro-coating)是(shi)(shi)利(li)用(yong)(yong)外加電(dian)(dian)場(chang)使(shi)懸(xuan)浮于電(dian)(dian)泳(yong)(yong)液中的(de)顏料和樹脂等微粒(li)定向遷(qian)移并沉(chen)積(ji)于電(dian)(dian)極(ji)(ji)之(zhi)一(yi)(yi)(yi)的(de)基底表面的(de)涂(tu)(tu)(tu)裝(zhuang)方(fang)法(fa)。電(dian)(dian)泳(yong)(yong)涂(tu)(tu)(tu)裝(zhuang)的(de)原理(li)發(fa)(fa)明于是(shi)(shi)20世紀30年代(dai)末，但開發(fa)(fa)這一(yi)(yi)(yi)技術(shu)并獲得工(gong)(gong)業應(ying)用(yong)(yong)是(shi)(shi)在(zai)1963年以后(hou)，電(dian)(dian)泳(yong)(yong)涂(tu)(tu)(tu)裝(zhuang)是(shi)(shi)近30年來發(fa)(fa)展起來的(de)一(yi)(yi)(yi)種(zhong)特殊(shu)涂(tu)(tu)(tu)膜形成(cheng)方(fang)法(fa)，是(shi)(shi)對(dui)水性(xing)涂(tu)(tu)(tu)料最具有(you)實際意義的(de)施(shi)工(gong)(gong)工(gong)(gong)藝(yi)(yi)。電(dian)(dian)泳(yong)(yong)工(gong)(gong)藝(yi)(yi)分為陽極(ji)(ji)電(dian)(dian)泳(yong)(yong)和陰(yin)(yin)極(ji)(ji)電(dian)(dian)泳(yong)(yong)。若(ruo)涂(tu)(tu)(tu)料粒(li)子(zi)帶(dai)負電(dian)(dian)，工(gong)(gong)件為陽極(ji)(ji)，涂(tu)(tu)(tu)料粒(li)子(zi)在(zai)電(dian)(dian)場(chang)力作用(yong)(yong)下在(zai)工(gong)(gong)件沉(chen)積(ji)成(cheng)膜稱為陽極(ji)(ji)電(dian)(dian)泳(yong)(yong)；反之(zhi)，若(ruo)涂(tu)(tu)(tu)料粒(li)子(zi)帶(dai)正(zheng)電(dian)(dian)，工(gong)(gong)件為陰(yin)(yin)極(ji)(ji)，涂(tu)(tu)(tu)料粒(li)子(zi)在(zai)工(gong)(gong)件上沉(chen)積(ji)成(cheng)膜稱為陰(yin)(yin)極(ji)(ji)電(dian)(dian)泳(yong)(yong)電(dian)(dian)源(yuan)涂(tu)(tu)(tu)裝(zhuang)工(gong)(gong)藝(yi)(yi)一(yi)(yi)(yi)般應(ying)用(yong)(yong)于汽(qi)車車身的(de)前處理(li)底漆防銹車身底漆，全方(fang)位無(wu)死角的(de)一(yi)(yi)(yi)種(zhong)電(dian)(dian)泳(yong)(yong)工(gong)(gong)藝(yi)(yi)，具有(you)水溶(rong)性(xing)、無(wu)毒、易于自(zi)動化控制等特點，迅速在(zai)汽(qi)車、建材(cai)、五(wu)金、家電(dian)(dian)等行業得到廣泛的(de)應(ying)用(yong)(yong)。
5、高壓無空氣(qi)噴涂
也稱無(wu)氣(qi)(qi)(qi)(qi)(qi)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)，是指使(shi)用高壓柱塞泵，直接將油漆(qi)加壓，形成高壓力的(de)(de)油漆(qi)，通過手動或者自動噴(pen)(pen)(pen)(pen)槍噴(pen)(pen)(pen)(pen)出槍口形成霧化氣(qi)(qi)(qi)(qi)(qi)流作用于(yu)物(wu)體表面(mian)（墻(qiang)面(mian)或木(mu)器(qi)面(mian)）的(de)(de)一種(zhong)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)方式(shi)(shi)。相對于(yu)有(you)氣(qi)(qi)(qi)(qi)(qi)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)而言，漆(qi)面(mian)均勻，無(wu)顆粒感。由于(yu)與空氣(qi)(qi)(qi)(qi)(qi)隔絕，油漆(qi)干燥、干凈。無(wu)氣(qi)(qi)(qi)(qi)(qi)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)可(ke)(ke)用于(yu)高粘度油漆(qi)的(de)(de)施工，而且邊(bian)緣清晰(xi)，甚至可(ke)(ke)用于(yu)一些有(you)邊(bian)界要求的(de)(de)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)項目。比如：鋼箱橋(qiao)(qiao)梁(liang)防腐噴(pen)(pen)(pen)(pen)漆(qi)，輪船船舶的(de)(de)防腐噴(pen)(pen)(pen)(pen)漆(qi)，工程機(ji)(ji)械行業，橋(qiao)(qiao)梁(liang)鐵(tie)路墊板或者減震支座的(de)(de)防腐噴(pen)(pen)(pen)(pen)漆(qi)，根據機(ji)(ji)械類型，也分為(wei)氣(qi)(qi)(qi)(qi)(qi)動式(shi)(shi)無(wu)氣(qi)(qi)(qi)(qi)(qi)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)機(ji)(ji)、電動式(shi)(shi)無(wu)氣(qi)(qi)(qi)(qi)(qi)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)機(ji)(ji)、內(nei)燃式(shi)(shi)無(wu)氣(qi)(qi)(qi)(qi)(qi)噴(pen)(pen)(pen)(pen)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)機(ji)(ji)等多(duo)種(zhong)。根據不(bu)同的(de)(de)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)工藝，選擇(ze)不(bu)同的(de)(de)噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)方式(shi)(shi)，智能噴(pen)(pen)(pen)(pen)涂(tu)(tu)(tu)機(ji)(ji)器(qi)人應(ying)用是未來發展的(de)(de)趨勢。
智能噴(pen)涂(tu)機器人系統結構(gou)與噴(pen)涂(tu)優點(dian)
一、自動噴(pen)涂機器(qi)人系統結構
1、對于空氣(qi)噴(pen)(pen)(pen)槍(qiang)和靜電轉杯噴(pen)(pen)(pen)涂，自動噴(pen)(pen)(pen)涂機器人可以(yi)直接修改噴(pen)(pen)(pen)漆量、霧(wu)化(hua)控制(zhi)(zhi)壓(ya)力、噴(pen)(pen)(pen)涂范圍控制(zhi)(zhi)壓(ya)力等噴(pen)(pen)(pen)涂參(can)數，大(da)大(da)提(ti)高了噴(pen)(pen)(pen)涂過(guo)程控制(zhi)(zhi)的效率。
2、從安全、可靠、高效的角度設計(ji)了(le)自動噴涂機器人(ren)控(kong)制器。內(nei)部(bu)(bu)模(mo)塊化設計(ji)結(jie)構，使功能升(sheng)級和維護更(geng)加方便。對于噴霧(wu)應用，內(nei)部(bu)(bu)有一個垂直空氣(qi)凈化控(kong)制模(mo)塊，其示(shi)教面板也是防爆的。
3、自動噴涂(tu)機器人的噴涂(tu)控制(zhi)柜通過標準模擬輸出模塊(kuai)控制(zhi)噴射(she)(she)量(liang)、噴射(she)(she)范圍、霧(wu)化等(deng)噴涂(tu)參數
4、自動(dong)噴涂(tu)機器人(ren)閉(bi)環控制系統能自動(dong)調(diao)節流量(liang)，提供穩定的液(ye)體流量(liang)和(he)良(liang)好的最終質量(liang)。集(ji)成微(wei)動(dong)變色(se)閥減少了變色(se)時間和(he)浪費。
5、所設計的自動噴(pen)涂(tu)機器人噴(pen)涂(tu)應用軟件可(ke)以靈活地應用于(yu)工作程(cheng)序中。預設的噴(pen)涂(tu)參數包(bao)括噴(pen)漆量(liang)、霧化(hua)控制壓(ya)力和噴(pen)涂(tu)幅(fu)度(du)控制壓(ya)力。利用該功(gong)能(neng)，可(ke)以在不需要輸送鏈實際運行的情況(kuang)下對(dui)在線(xian)跟(gen)蹤程(cheng)序進行測(ce)試，從而提高教學效率(lv)。
6、智能(neng)噴(pen)涂機(ji)(ji)器(qi)(qi)人(ren)(ren)基本配置如下：機(ji)(ji)器(qi)(qi)人(ren)(ren)本體，自動(dong)(dong)(dong)(dong)(dong)噴(pen)涂工藝控制(zhi)(zhi)系(xi)統(tong)(tong)(tong)，自動(dong)(dong)(dong)(dong)(dong)噴(pen)控系(xi)統(tong)(tong)(tong)，供(gong)漆(qi)系(xi)統(tong)(tong)(tong)，涂料(liao)自動(dong)(dong)(dong)(dong)(dong)配比(bi)混合系(xi)統(tong)(tong)(tong)，PLC控制(zhi)(zhi)系(xi)統(tong)(tong)(tong)，同(tong)步跟(gen)蹤(zong)系(xi)統(tong)(tong)(tong)，工件(jian)自動(dong)(dong)(dong)(dong)(dong)識別系(xi)統(tong)(tong)(tong)，機(ji)(ji)器(qi)(qi)人(ren)(ren)自動(dong)(dong)(dong)(dong)(dong)調用(yong)程序，自動(dong)(dong)(dong)(dong)(dong)清洗自動(dong)(dong)(dong)(dong)(dong)換色功能(neng)，安全(quan)互鎖(suo)控制(zhi)(zhi)，周邊配套安裝設備，機(ji)(ji)器(qi)(qi)人(ren)(ren)地軌移動(dong)(dong)(dong)(dong)(dong)滑臺(tai)，自動(dong)(dong)(dong)(dong)(dong)噴(pen)涂旋轉臺(tai)，靜(jing)電噴(pen)槍(qiang)或者靜(jing)電旋杯等主(zhu)要硬件(jian)配置。
二、采用自動噴(pen)涂(tu)機器(qi)人噴(pen)涂(tu)優勢
1、柔性大(da)、工作(zuo)范圍大(da)大(da)；
2、提高(gao)噴涂質量和材料利用率；
3、易于操作(zuo)和維護，可(ke)離線編程，大(da)大(da)的(de)縮短現場(chang)調(diao)試時(shi)間；
4、設備利(li)(li)用(yong)率高(gao)。噴涂機(ji)(ji)器(qi)人(ren)的(de)(de)利(li)(li)用(yong)率可(ke)(ke)達90%-95%。該自動(dong)噴涂機(ji)(ji)器(qi)人(ren)具有(you)精度高(gao)、靈活性好、智能化等優點。另外，在機(ji)(ji)器(qi)人(ren)涂裝過(guo)程(cheng)中，可(ke)(ke)以對機(ji)(ji)器(qi)人(ren)進行檢測(ce)、控制、優化、調(diao)度、管(guan)理和決(jue)策，從(cong)而提高(gao)產量，提高(gao)質量，降低成本，減少資源消耗和環境污(wu)染。同時(shi)，也是工業自動(dong)化水(shui)平的(de)(de)高(gao)體現。
杰瑞斯智能噴涂機器人