Designing and improving the controller of electrostatic powder paint spraying robot

نوع: Type: Thesis

مقطع: Segment: masters

عنوان: Title: Designing and improving the controller of electrostatic powder paint spraying robot

ارائه دهنده: Provider: Arman fotoohi

اساتید راهنما: Supervisors: Dr. Mehdi Karimi

اساتید مشاور: Advisory Professors:

اساتید ممتحن یا داور: Examining professors or referees: Dr alireza shoshtari Dr amin imani

زمان و تاریخ ارائه: Time and date of presentation: 2025

مکان ارائه: Place of presentation: 55

چکیده: Abstract: This thesis presents the design, implementation, and practical operation of an electrostatic powder coating robot control system. First, the overall structure of the coating line—including the overhead conveyor, surface preparation stations, drying unit, and spraying section—is described. The process of selecting and installing the main components, such as the OM_TRN_110 spray gun, cyclone powder recovery system, central controller, inverter, light curtain sensors, and linear actuator mechanism, is then explained. The selection criteria for the industrial light curtain sensor—precision, environmental resistance, response speed, and synchronization capability with the controller—are analyzed. The sensor creates an infrared curtain to detect the dimensions and height of each passing workpiece and transmits an analog output signal to the PLC. In the software section, the PLC control logic was implemented in five main stages: converting the analog signal (0–10 V) to the actual height value (0–100 cm) using the LCNV function; counting the parts via counter C200; storing height data in the shift register T_SHF; reprocessing data for control output; and finally, sending position and speed commands to the drive using the HSPSO function. This control structure enables full coordination among part passage, height measurement, and robot motion range adjustment. In the practical phase, several improvements were made, including relocating the sensor to prevent thermal damage, optimizing the spray gun angle, and reinforcing conveyor clamps to enhance the electrical charge of the workpieces. The final results demonstrate that the integration of smart sensors, PLC-based control algorithms, and mechanical redesign led to increased coating accuracy, improved uniformity, reduced powder consumption, and enhanced overall efficiency of the coating line.