A Geodesic-Based Robot Trajectory Planning Approach for Cold Spray Applications
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A Geodesic-Based Robot Trajectory Planning Approach for Cold Spray Applications Zhenhua Cai1 • Xufeng Liang1 • Beigao Chen1 • Chunnian Zeng1 • Chen Chen1 Zixin Mu1 • Tingyang Chen1
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Submitted: 10 September 2018 / in revised form: 10 May 2019 / Published online: 4 June 2019 Ó ASM International 2019
Abstract This paper presents a geodesic-based robot trajectory planning approach to fulfill the increasingly high reproducibility and coating quality requirements for cold spray applications. First, on the basis of Gauss–Bonnet theorem, the selection of a reference curve is discussed with the aim of minimizing the entire length of subsequent offset curves. An index sequence-based offset curve is created, and its discrete algorithm is then introduced to generate the optimal trajectory. Finally, a comparative experiment and analysis indicate that the presented trajectory planning approach can achieve coating thickness homogeneity. Keywords cold spray curve discrete free-form surface geodesics optimal trajectory
Introduction Coupled with the increasing demand in the manufacturing industry, various complex free-form surfaces are currently widely used in cold spray applications, leading to the necessity of developing advanced robot trajectory planning approaches for performing cold spraying tasks accurately and efficiently. Thermal spraying of free-form surfaces requires an exact control of torch/gun handling during processing in order to produce homogeneity in the coating & Beigao Chen [email protected] Zhenhua Cai [email protected] 1
Automation School, Wuhan University of Technology, Wuhan 430000, China
microstructure and functionality (Ref 1). An optimal robot trajectory should also guarantee the short full coverage trajectory when passing over the complex surface, thereby helping to shorten cycle time and minimize material consumption. Unlike the online teaching method, off-line programming transfers robot programs created through simulation to the actual robot cell (Ref 2). It does not interfere with production of the robot program and is prepared on an external computer outside of the production environment. Despite current research advances in off-line programming for cold spray applications, there still exist many unsolved issues. For example, it may be quite difficult to manually select the proper trajectory points in the graphic environment of off-line programming software and may therefore be hard to ensure program precision for complex industrial workpieces. Thus, in most cases, the developed off-line programming package has focused on the trajectory generation method. Different from paint coating, the cold spray coating has no fluidity, which is more sensitive to trajectory precision and cold spray parameters (like scanning step, spray distance, etc.); thus, many prior contributions focused on this research subject. For example, Vivekanandhan et al. (Ref 3) presented a mathematical analysis for the generation of base and offset mesh surfaces, wherein the coating pistol is inc
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