Spray Painting Robot With Low Cost Autom

International Journal of Advances in Engineering and Management (IJAEM)
Volume 3, Issue 12 Dec 2021, pp: 1408-1416 www.ijaem.net ISSN: 2395-5252
Spray Painting Robot with low cost

automation
Tanzim KhanPathan1, Apurva R Deshmukh2, Sanjivani A
Kanwate3
1Junior Engineer (Mechanical) NAHEP CAAST VNMKV, Parbhani
2Junior Engineer (Electrical) NAHEP CAAST VNMKV, Parbhani
3Junior Engineer (Computer) NAHEP CAAST VNMKV, Parbhani
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Date of Submission: 15-12-2021 Revised: 27-12-2021 Date of Acceptance: 30-12-2021
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ABSTRACT: The purpose of this paper is to design, Paint application on the external surfaces is
develop, and execute a low-cost automatic spraying simple and straightforward, regardless of the pipe's
operational robot. This contributes to the creation of huge diameter or length. However, painting the interior
low-cost spraying robots. Despite developments in walls of the pipe gets more challenging as the pipe
robotics and their widespread applications, today's lengthens. Because of the length of the pipe, painting is
industry demands for automated spray painting are on not possible as the inner walls become inaccessible. As
the rise. Interior and exterior surface spraying a result, a unique device is required to cover the whole
operations have had nothing in common in terms of inner-wall of the pipe, regardless of its diameter or
research. Human operators may be exposed to risks length. This paper gives design of spray painting robot
such as skin disease and respiratory difficulties as a which easily paint inner wall of object.
result of the spraying paints. Furthermore, the nature of
the painting method, which necessitates repetitive II.LITERATURE REVIEW
work and hand rising, makes it tedious, Kahane et al. [1] and Warszawsky et al. [2]
time-consuming, and effort-intensive. When robots are created a robot for interior finishing jobs such as
correctly incorporated into jobs, the entire operational painting, plastering, tiling, and masonry. They
process can be better managed, resulting in cost employed a typical robot arm with 6 DOF (Degrees of
savings in human labour and time. Furthermore, it Freedom), 1.7 m reach, and a 30 kg payload.Their
would provide the opportunity to limit or eliminate robot was mounted on a three-wheeled mobile robot,
human exposure to tough and dangerous situations, providing an additional three degrees of freedom. The
resolving the majority of the issues associated with robot can move between workstations and deploys four
safety when many operations are occurring at the same stabilising legs at each location. Due to its 500 kg
time. The creation of an automated robotic painting weight, this robot cannot be employed in residential
system is motivated by these factors. To emphasise buildings. When compared to human painting, wall
accuracy in system proximity sensors and controller is painting saves around 70% of the time, and ceiling
used in the project. painting saves an additional 20%.
Keywords :.IR sensor, Spray Painting Robot, Worm Andreas Pichler et-al. [3], An automatic spray
and Worm wheel painting approach for unknown parts has been devised.
There are no pre-existing CAD models or other
I. INTRODUCTION information about the parts included in the system's
Normally, spray painting is done manually, input. Geometry models from a laser scanning system
with spray guns fixed to a stationary base, or with a and customized feature extraction methods are used to
six-axis robot that follows a complex trajectory that is completely specify the parts. Previously, only one laser
entirely automated. Robots paint a wide variety of scanner was used to scan the parts. The scanner-visible
different items at high production rates. For example, portions of the surfaces were modeled in a 3D
some vehicle manufacturers demand finishers to paint geometry model, which was used to autonomously
all plastic trim elements at the same time in order to produce spray gun motions. A collision avoidance mod
achieve better color matching; this is a perfect use for a automatically avoids collisions between the spray
robot. After the robot has been programmed, it paints cannon and the part and conveyor system.
millions of pieces with minor differences.
DOI: 10.35629/5252-031214081416 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 1408
BerardoNaticchia et-al. [4]The paper main frame at system, man + machine interactions, No.
provides information on Robotic spray painting of controls, position of controls, working environment
thickness is measured in [µ m] by considering different of machine, chances of failure, safety measures to be
spray painting parameters like paint flow , viscosity, provided, servicing aids, ease of maintenance, scope of
gravity surface tension easily deposition of paint improvement, weight of machine from ground level,
quality measured values. total weight of machine and a lot more.
Sorour et al. [5] proposed a full-scale wall
painting robot that was built around a simple two-link A. SYSTEM DESIGN
manipulator mounted on a mobile base. The system In system design we mainly concentrated on the
operated, although at a slow rate. Their work was following parameters: -
inspired by the fact that the painting arm does not need 1. System Selection Based on Physical Constraints
to be a 6 DOF arm because it is overqualified for the While selecting any machine it must be checked
painting job, thus it was substituted with a basic 2 link whether it is going to be used in a large-scale industry
arm. or a small-scale industry. In our case it is to be used by
Aris et al. [6] proposed a full-scale system for a small-scale industry. So space is a major constrain.
ceiling painting with 3DOF without taking the The system is to be very compact so that it can be
platform into account and a working envelope of adjusted to corner of a room. The mechanical design
(84x72x122 cm). A 46m2 ceiling was painted in 3.5 has direct norms with the system design. Hence the
hours, which is 1.5 times faster than hand painting.This foremost job is to control the physical parameters, so
robot, on the other hand, is large, has a small work that the distinctions obtained after mechanical design
space, and is mainly designed to paint the ceiling. can be well fitted into that.
Shigeru Ikemotoa et al.[7]The purpose of his 2. Arrangement of Various Components
study is to create a learning system for automotive Keeping into view the space restrictions the
coating and painting operations. The characteristics of components should be laid such that their easy removal
professional spray gun handling for vehicle repair or servicing is possible. More over every component
painting were investigated and compared in his study. should be easily seen none should be hidden. Every
When comparing spray gun handling between possible space is utilized in component arrangements.
specialists and non-experts, the results showed that 3. Components of System
experts have a longer running length, longer spray As already stated the system should be compact
time, greater speed, and a narrower spray gun swing enough so that it can be accommodated at a corner of a
range. room. All the moving parts should be well closed &
A wall painting robot was designed by compact. A compact system design gives a high
Pkeerthana et al. [8] using a conveyor belt, shaft, spray weighted structure which is desired.
gun, and controller unit. Because there were fewer 4. Man Machine Interaction
moving parts, it performed as expected. The friendliness of a machine with the operator that is
an autonomous painting robot that comprises of an operating is an important criteria of design. It is the
arm that scans the walls vertically and is mounted on a application of anatomical & psychological principles
movable robot base that allows for lateral feed motion to solve problems arising from Man – Machine
to cover the painting surface. To adjust the motion relationship. Following are some of the topics
limit and change direction in the room area, ultrasonic included in this section.
sensors are fitted on the arm and mobile base. This  Design of foot lever
effective project proposed by VaniMukundan et al.[9]  Energy expenditure in foot & hand operation
 Lighting condition of machine.
III DESIGN OF ROBOT 5. Chances of Failure
Design of robot consists of application of The losses incurred by owner in case of any failure are
scientific principles, technical information and important criteria of design. Factor safety while doing
imagination for development of new or improvised mechanical design is kept high so that there are less
machine or mechanism to perform a specific function chances of failure. Moreover periodic maintenance is
with maximum economy & efficiency. Hence a careful required to keep unit healthy.
design approach has to be adopted. The total design 6. Servicing Facility
work, has been split up into two parts; The layout of components should be such that easy
• System design servicing is possible. Especially those components
• Mechanical Design. which require frequents servicing can be easily
System design mainly concerns the various disassembled.
physical constraints and ergonomics, space 7. Scope of Future Improvement
requirements, arrangement of various components on
Arrangement should be provided to expand the scope  Which will almost satisfy the functional needs.
of work in future. Such as to convert the machine Assumptions must always be on the safer side.
motor operated; the system can be easily configured to  Selection of factors of safety to find working or
required one. The die & punch can be changed if design stress is another important step in design of
required for other shapes of notches. working dimensions of machine elements. The
8. Height of Machine from Ground correction in the theoretical stress values are to be
For ease and comfort of operator the height of machine made according in the kind of loads, shape of parts &
should be properly decided so that he may not get tired service requirements.
during operation. The machine should be slightly  Selection of material should be made according to
higher than the waist level, also enough clearance the condition of loading shapes of products
should be provided from the ground for cleaning environment conditions & desirable properties of
purpose. material.
9. Weight of Machine Provision should be made to minimize nearly adopting
The total weight depends upon the selection of material proper lubrications methods. Following are
components as well as the dimension of components. components of system.
A higher weighted machine is difficult in Motors with Assembly:
transportation & in case of major breakdown, it is Two DC motors with following specification are used:
difficult to take it to workshop because of more weight. Voltage : 12 Volt DC
Power = 50 watt
B.MECHANICAL DESIGN Speed = 500 rpm
Mechanical design phase is very important Mounting : Foot mounted
from the view of designer as whole success of the Motor Assembly consist of following parts
project depends on the correct deign analysis of the  Pinion Shaft : Pinion shaft is mounted at its square
problem. Many preliminary alternatives are end on the worm gear box output side, where as the
eliminated during this phase. Designer should have pinion is held on the other side of the pinion shaft.
adequate knowledge above physical properties of  Main shaft: Main shaft is held at one end in ball
material, loads stresses, deformation, failure. Theories bearing 6201zz in the main bearing housing which is
and wear analysis, He should identify the external and welded to the base frame. Whereas the side stand is
internal forces acting on the machine parts welded at other end of shaft.
These forces may be classified as ;  Holder bracket: Holder bracket is an standard forged
1. Dead weight forces part which hinges the side stand at one end, and spring
2. Friction forces arrester pin-1 is welded at the other end. This pin holds
3. Inertia forces one end of the helical tension spring. The holder
4. Centrifugal forces bracket is welded to the boom.
5. Forces generated during power transmission etc
 Base frame:Base frame comprises of the base plate,
 Designer should estimate these forces very boom, motor plate and the gear box plate. These are
accurately by using design equations .If he does not support members that hold the assembly together.
have sufficient information to estimate them he should
 DP/DT switch: The DP/DT switch is an electrical
make certain practical assumptions based on similar
direction control switch which changes the direction of
conditions
rotation of the motor and there by controlling the
motion of the side stand.
Figure 1 Motor Assembly
IV.CONSTRUCTION & WORKING movement of spray gun fitted on the worm and worm
1. Base Frame: The Primary base frame is the base wheel. Microcontroller unit is provided with the 5V
element provided with castor wheels, The primary base signal and as soon as the supply is ON, LCD gets
is made of mild steel square tube and mild steel plate. It initialized. The controller sets to setting mode and
supports the entire assembly of the spray paint system painting distance are given as input to the
robot. microcontroller. The microcontroller controls the
2. Vertical motion system: The vertical motion system rotation of DC motor based on the distances given in
comprises of the screw and nut, lifter screw held in two order to control wheel movement. When IR receiver
ball bearings and nut connected to the carrier. Rotation receives the signal, the worm wheel moves and the
of screw is converted to translation of the spray paint spray gun goes to ON condition and if the worm wheel
system which moves it up or down stops, the spray gun goes to OFF condition. It contains
3. Paint storage: Paint storage is done in a small tank of relays for the control of forward and backward
1 to 5 liter capacity mounted on the structure. The movement of the stepper motors. When the
compressed air is supplied through the chamber to microcontroller receives the signals from IR sensor, it
carry the paint to the spray rotor end. will be taking a decision to operate the machine. This
4. Paint application: Paint application is done by pulse signal received from IR sensor circuit when there
means of a spray gun which is reciprocated in linear is any object
guide by crank and connecting rod mechanism 8. IR sensor
operated by motor, for spraying application done by IR sensor is used for this project. IR (Infrared) is the
compressed air received from air compressor. typical light source being used in the sensor for robot to
6. Worm and worm wheel: Worm and worm wheel detect opaque object. IR Sensor (IR Receiver and IR
allow horizontal(Left and right) and vertical(Up and Emitter) the basic principle of IR sensor is based on an
Down) motion of spraying gun. The worm is made of IR emitter and an IR receiver. IR emitter will emit
case hardened steel 14C6 whereas the worm wheel is infrared continuously when power is supplied to it. On
made of Cast iron. the other hand, the IR receiver will be connected and
7.Control circuit: The paint quality i.e. the thickness of perform the task of a voltage divider. IR receiver can
paint will be controlled by the control the speed of the be imagined as a transistor with its base current
motor so also the speed of the translation of the setup determined by the intensity of IR light received
will be controlled by the the speed of translation for 9. Castor wheels: Castor wheels with moving platform
controlling position of spray Gun microcontroller is make robot easy to move towards object. This is base
used. The microcontroller used in the controller unit is of the machine which enables transportation of the
LPC2148 ARM microcontroller. The microcontroller set-up or when applied with motorized motion can
unit is used to control the two motors and the enable automatic translation while object painting.
Figure 2.CAD Drawing of Spray Painting Robot
V RESULT
Spray painting robot was design by considering different parameters.Table 1 shows Spray painting robot
components with design calculation
Table 1Design calculation of Spray painting Robot components

Sr Compone Assumptions Results
. nt
N
o
1 The lower value of Kw =7.46
WORM torque is on the wheel = Kw
AND 1.98 x 106 N-mm As the drive
WORM is capable of
WHEEL transmitting
(WORM 7.46 Kw and
GEAR we intend to
BOX) transmit
0.08Kw the
drive is safe.
2 Power = 20 watt m=1.35
GEAR Speed = 18 rpm,b = 10 selecting
FOR m standard
SCREW No.of teeth on pinion = module =1.5
10 mm
No. of teeth on Gear =
30
GEAR DATA
No. of teeth on pinion
=10
Module = 1.5 mm
No. of teeth on gear
=30

. nt
N
o
3 Power = 20 watt m=0.6
GEAR Speed = 18 rpm selecting
FOR b = 10 m standard
CRANK No.of teeth on pinion = module =1.5
10 mm
No. of teeth on Gear =
82
GEAR DATA
No. of teeth on pinion
=10
Module = 1.5mm,No.
of teeth on gear =82
4 ULTIMATE TENSILE fs act =
GEAR STRENGTH=800 17.48
SHAFT N/mm2, YEILD N/mm2
STRENGTH=680N/m As fs act
m2 < fs all
Assuming minimum Pinion shaft
section diameter on is safe under
input shaft = 21 mm torsional
GEAR BORE IS load.
SATANDARD 21MM
d = 21 mm
5 Assuming pin diameter Shear stress
CRANK =10mm,Force =318 N = 4.04
PIN TENSILE N/mm2
STRENGTH=800N/m Shear stress
m2, = 4.04/mm 2
YEILD < 144
STRENGTH=680N/m N/mm2
m2 Design of
crank pin is
safe.
6 In our case; C = 517.9 N
(SELECTI Radial load FR =318 AS; required
ON OF N dynamic of
BALL L= 4.32 mrev bearing is
BRG)CRA less than the
NK rated
dynamic
capacity of
bearing;=
Bearing is
safe.
7 In our case; C = 517.9 N
(SELECTI Radial load FR =318 AS; required
ON OF N dynamic of
BALL L= 4.32 mrev bearing is
BRG)SCR less than the
EW rated
dynamic
capacity of

. nt
N
o
bearing;=Be
aring is safe.
8 Force =318 N Shear stress
SLIDER Assuming pin diameter = 4.04
PIN =10mm N/mm2
MATERIAL Shear stress
SELECTION: =
TENSILE 4.04/mm2<
STRENGTH=800N/m 144 N/mm2
m2, Design of
YEILD SLIDER pin
STRENGTH=680N/m is safe.
m2
9 Tmotor = 4.7 N-m Direct
SCREW Torque at screw = 4.7 x Tensile or
43/12 =16.84 N-m Compressiv
Helix Angle= 5.190, e stress due
W =5826.9N to an axial
W = 582.6 kg load :-
This is lifting capacity a)Compressi
of screw using the ve stress:
motor specifications fc act =
MATERIAL 16.82
SELECTION: N/mm2
TENSILE As fc act <
STRENGTH=600N/m fc all ;
m2, Screw is safe
YEILD in
STRENGTH=380N/m compression
m2 .
b)Torsional
shear stress
:-
fs act = 9.26
N/mm2
As fs act <
fsall ; the
screw is safe
in torsion.
C) Bearing
Pressure:-
Safe bearing
pressure=11
-17(N/mm2),
n = 4.99
d)Shear
stress due to
axial load
fs act = 5.88
N/mm2
As ; fs act <
fs all , the

. nt
N
o
screw
threads are
safe in
shear.
Stresses due
to buckling
of screw:
-Wcr
=96.21x103
N
As, The
critical load
causing
buckling is
high as
compared to
actual
compressive
load of
5.826KN .
10 NUT Material Selection: n=5
Allowable tensile AS ; n = no
stress=400N/mm2, of the
Allowable shear threads in
stress=210N/mm2 contact.
ln =36 mm
Considering
length of nut
=
36mm
36mm36
mm
VI CONCLUSION task,”Computer-Aided Civil and Infrastructure

The conceptual design of a Spray painting Engineering,vol.19,2004,pp.394-410
robot to be used for painting external and interiorparts [2]. Y.Warszawsky,Y.Rosenfield:”Robots for
of objects had been described. The robot uses a roller interior finishing works in buliding:feasibility
fed with painting liquid and keeps contact with the analysis,”ASCE Journal of construction
parts. By worm and worm wheel mechanism and IR Engineering and
sensor robot can scan both vertically and horizontally Management,vol.120(1),1994,pp.132-151
the paint objects. The robot can maneuver to adjust [3]. Andreas Pichler,Markus Vincze Henrik
itself in front of the object. The criteria for system Andersen,Kurt Hausler Profactor”A Method for
design had been outlined and the system was Automatic Spray Painting of Unknown Parts
implemented and tested. However, there is much scope ”,International Symposium on Robotics,october
for system improvement in the future to increase the 7-11,2002
painting rate and simplify the system design [4]. Berardo Naticchia, Alberto Giretti and
Alessandro Carbonari, “Setup of an Automated
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[5]. M. Sorour, M. Abdellatif, A. Ramadan and A.
AboIsmail, “Development of Roller-Based
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[6]. I. Aris, A. K. Parvez Iqbal, A. R. Ramli and S.
Shamsuddin. “Design and development of a
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[7]. Shigeru Ikemotoa, MengyuanLiaoa, Yuka
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International Journal of Advances in Engineering and Management (IJAEM)

Volume 3, Issue 12 Dec 2021, pp: 1408-1416 www.ijaem.net ISSN: 2395-5252

Spray Painting Robot with low cost

Figure 1 Motor Assembly

Figure 2.CAD Drawing of Spray Painting Robot

Table 1Design calculation of Spray painting Robot components

Sr Compone Assumptions Results

Sr Compone Assumptions Results

Sr Compone Assumptions Results

VI CONCLUSION task,”Computer-Aided Civil and Infrastructure

Robotic Systems, Vol. 4, No. 4, pp. 407-416,

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