Total Automated Spray System

Contents
Page No.
1. Introduction 2-3
2. Instruction 4
3. Components. 5-6
4. Cautions 7
5. Troubleshooting 8
6. Do’s and Dont’s 9
7. System Outline 10-12
8. Procedures for Programming 13-18
9. Patterns 19-21
10.Parameters 22-23
11.Components details 24-32
12. Electrical Connections 33-35

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Introduction
Spray painting is a painting technique where a device sprays a
coating (paint, ink, varnish, etc.) through the air onto a surface. The most
common types employ compressed gas usually air to atomize and direct
the paint particles. Spray guns evolved from airbrushes, and the two are
usually distinguished by their size and the size of the spray pattern they
produce. Airbrushes are hand-held and used instead of a brush for
detailed work such as photo retouching, painting nails or fine art. Air
gun spraying uses equipment that is generally larger. It is typically used
for covering large surfaces with an even coating of liquid. Spray guns
can be either automated or hand-held and have interchangeable heads to
allow for different spray patterns.
Spray application is the most common method of liquid painting
and can be applied manually for low production or automatically with
reciprocators or robots for high production rates. Several types of spray
systems are available such as, "airless", where paint is sprayed under
high pressure without atomizing air or, "air spray" including air-assisted
airless, High

Volume Low Pressure (HVLP) and conventional high pressure air spray.
Typically, spray is the least transfer efficient application method and can
range from 25% to 50% for non-electrostatic guns and 45% to 70% for
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electrostatic spray. Electrostatic application electrically charges the paint

particles that are then attracted to a grounded, conductive part, usually
metal.
While paint can be sprayed in an open area if proper health and
safety precautions are taken, most sprayed liquid paints are applied in a
paint "booth" or enclosure that contains the overspray and fumes. A
booth also limits dirt or other outside contaminants from being
introduced to the paint operation.

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Instructions

 Spray a test shot onto a piece of plywood to see the spray pattern
that needs to be produced. You can adjust your technique and
hold the gun closer or further from the target, depending on the
spray pattern.
 Surface Preparation: Thoroughly clean the area to be repaired
with wax/grease remover (glass cleaner or similar can be used as a
substitute) & let dry completely. Assure the surface is free of wax,
oil, and other surface contaminates by applying wax/grease
remover to a clean lint free towel (blue shop towel) and use it to
clean paint surface to (only apply wax/grease remover to the towel,
never directly on paint).
 Make sure compressor air pressure is sufficient for the operating
spray gun.
 Lock the wheels when operating the system in order to avoid
movement of the equipment.
 Initiate the program data from the left bottom corner of the
specimen.

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List of Components

1. Linear Actuators- 4nos(with different specifications and controller

with remote)
*2 for Tilting (load-6000n, stroke-250mm)
*2 for Moving the frame (load-6000n, stroke-
200mm)
2. Servo Drives - 3nos
* Each for X-axis, Y-axis and Rotary.
3. Servo Motors - 3nos
* Each for X-axis, Y-axis and Rotary
4. Screw rods - 2nos
* X-axis - 25mm dia & 1200 mm length
* Y-axis- 25 mm dia & 1200mm length
5. End supports for screw rods- 4nos
6. Guide rails - 5nos(each of 1500mm)
7. Guide block- 4nos
8. PLC Controller Box-2nos
9. HMI Display- 1nos
10. SMPS - 24volts
11. C- Channel for frame fabrication

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12. Spray gun- 2nos

*HP 64s
*HP-59S
13. Caster wheels with 200 kg load capacity- 4nos
14- Compressor with 10bar maximum pressure- 1no
15. Pressure controller unit- 1nos(FRL-Filter Regulator Lubricator)
16. Digital angle box.
17.Couplings- 2nos(Riddhi R95)
18.Stepper motor and stepper drive- 1nos each.

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Cautions

 Make sure proper power supply is available.

 Keep the pressure at required level.
 Make sure the nozzle of spray gun is clean properly
 Make sure program data are within the limits
 Check the angle of tilt for proper spray
 Measure the distance of spray nozzle to specimen fixing frame and
do proper adjustment if required.
 Check that Specimen is fixed rigidly to the frame.
 Conduct the spray only in proper spray booth and ensure proper
exhaust available.

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Trouble Shooting

 In case if the program stops at any point then turn off the
system and power supply and re-start the system to run
again.
 Miss alignments of coupling connected between screw rod
and servo motor can be fixed mechanically.
 If spray gun air supply is not sufficient adjust the air
controller screw in the spray gun.
 Also if flow supply is insufficient then adjust the flow
control screw provided in the spray gun.
 In case if the auto start does not respond then return to home
page and come back to auto page to load the program and
then auto start it.

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Do's and Dont's

 Don't allow the spray gun to dry, clean during wet condition
only.
 Don't run the X and Y system at high speed in manual mode.
It may damage the limit switch or misalign the screw rod
assembly when direction changes at high speed(500-1000rpm
is optimum)
 Don't feed data beyond the system limits.
 Don't hit the servo motors with hammer or heavy things.
 Handle the spray gun removal system with care.
 Clean the system after every use in order to avoid paint
accumulation.
 Do press home position switch after turning on the system
and move the joystick away from home a bit in order to guide
the system its position from home.
 Don't press and release emergency button multiple times at a
time, give a time period of at least 5 seconds between each
press and release of emergency.
 Don't run the actuators continuously for more than 2mins
since the actuators run time is 2mins for every 20mins.

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System Outline

Fig 1: Front view system outline.

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Fig 2: Overall view with control box.

Fig 3: Spray gun along with stepper motor.

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Fig 4: Control box.

Fig 5: Control box inside view.

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PROCEDURES FOR PROGRAMMING

Manual Mode

Fig 6. Manual mode or home page.

In manual mode the movement of the spray gun can be controlled (to x
and y direction) by using the jog (joy stick) that is provided. The speed
of the movement must be entered for both directions in "Settings page"
provided for both direction.

1. Set the speed of x direction.(500rpm recommended)

2. Set the speed of y direction.(500rpm recommended)
3. Use joystick to manually operate the movement of spray gun.

Auto Mode: Allows you to select the saved programs and to run them.
Go to Home: Use this button for positioning the spray gun to
origin(X=0, Y=0) 0f the frame.

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Setting Page Login.

Fig 7: Login Page and Admin Page.

For security purpose the automode parameters are secured with a admin
login page which is named as 'SETTINGS' . Only the person with
authority can control the usage of these fields.
 Click on settings button & enter the user name & password
provided then unlock and go back to the main page using the back
button.
 Enter the name of user(currently it is "admin")
 Enter Password(currently it is "1234")
 Press unlock switch and go back to home page .
 Then again select settings from home page which will redirect to
Programming page and another setting page for parameters to be
given to the system.

NOTE: Only after entering the login page user can program or
make changes to the existing one. Creating a new program or deleting a
existing program will also require user login. Even the manual mode
speed, Spray gun Stepper motor speed and rotary speed can only be
changed after entering the login page.
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Auto Mode Page

Fig 8. Auto Mode Page.

This page can be accessed by any user without the login of admin. In
this page any previously saved programs can be selected and loaded to
run the system.
In order to select previous programs;

 Press the down arrow corresponding to pattern, select the pattern

from which the spray needs to be conducted(out of 6 patterns)
 Press the down arrow corresponding to model, the programs
corresponding to the selected patterns will be listed which are
saved earlier. Select the required program.
 Then press Load button to load the selected program.
 Click on Auto Start to run the program.
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Programming Mode

Fig 9: Programming page.

Steps to create , delete or make changes in program.

1. Click on home position.

2. Click on settings button & enter the user name & password
provided then unlock and go back to the main page using the
back button.
3. Then again press settings to create ,delete or make changes to
the program.
4. To create program select "New" & enter the parameters as
required for the program & "Save"; To Delete program
select pattern n model then press "Delete"; To make changes

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select pattern & model change the parameter and then

"Save".
5. To Run the program go to auto mode page and then follow
the auto mode page instructions.

Fig 10: Programming page with the parameters.

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To Run the program:

Fig11: Auto mode program selection page.

1. After entering into auto mode select the pattern & model .
[even the program parameters are displayed to have a visual
look]
2. click on 'Load' button to load the program.
3. Select auto start to run the program automatically.

By pressing "next" button you can access to "setting page " and
then follow the auto mode page instructions.
Note: we can control the spray gun trigger level in the middle of
auto run (which doesn't interrupt the real time run program) by long
press on 'Spray On' & Spray Off'. The RPM of spray gun actuation can
also be changed by clicking on provided rpm .
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Patterns:

1. X- ONLY:
This mode allows the spray gun to travel on in x- axis, and restricts
the movement along y-axis direction.

2. Y - ONLY:
This mode allows the spray gun to travel on in y axis, and restricts
the movement along x direction.
The steps to perform y only mode is similar to x only mode, only
difference being we select y in every step and give speed, distance &
cycles to y axis

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3. X STEP Y:

In this pattern , the spray direction will be more on horizontal zone

than vertical. if there is more than 1 cycle the spray follows the path in
reverse direction .
4. Y STEP X:

In this pattern , the spray direction will be more on vertical zone

than horizontal. if there is more than 1 cycle the spray follows the path
in reverse direction .

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5. X STEP Y P2:

In this pattern , the spray direction will be more on horizontal zone

than vertical. if there is more than 1 cycle the spray directly comes back
to origin of the program and continues to follow the same pattern in
forward direction.
6. Y STEP X P2:

In this pattern , the spray direction will be more on vertical zone

than horizontal. if there is more than 1 cycle the spray directly comes
back to origin of the program and continues to follow the same pattern in
forward direction.
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Parameters

Fig 12: Parameters a.

Fig 13: Parameters b.

1. X Speed: Defines the speed along X direction
2. Y Speed: Defines the speed along Y direction
3. X Distance: Defines the length along X direction
4. Y Distance: Defines the length along Y direction

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5. Step Length: Determines the vertical step distance in x step

y and x step y p2 & also determines the horizontal step
distance in y step x and y step x p2 patterns.
6. Num Cycle: It is a loop which determines the no of time the
pattern repeats .
7. Back Distance: Distance travelled to move towards home
position from origin in order to make the spray on and to
control the spray trigger limit.
8. Back Speed: Speed at which back distance moves.
9. X Position: To enter the origin of the specimen along X- co-
ordinates.
10. Y Position: To enter the origin of the specimen along Y- co-
ordinates.

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Components Details

Fig 14: The Horizontal Quick-Release Toggle Clamp.

With its sturdy construction and efficient design, this essential tool
ensures that you achieve a rock-solid grip on your work piece, thus
providing a hold that won’t slip. Features a low height design and
mechanism to allow for maximum clearance. Vinyl colored grip for easy
identification and comfort. Zinc-plated coating for corrosion resistance.
Retracted clamp will allow for vertical removal of clamped item. This
versatile and handy clamp makes woodworking perfection a breeze.
Small tool, big help! Clamp Base: 1-3/8” x 1-1/2”. Mounting Slots: 1/4” x
3/8” spaced 7/8” x 7/8”. Clamp reach range, from front of clamp base: 1-
1/8” - 2-5/8”. Bolt length, including rubber foot: 2-1/2”. Clamp foot
adjustable range from bottom of clamp arm: 1-1/8” - 1-3/4” . Clamp
height when clamped: 2”. Total length, including handle, when clamped:
7”.

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Fig 15: Electrical Limit Switch.

In electrical engineering a limit switch is a switch operated by the

motion of a machine part or presence of an object.

They are used for controlling machinery as part of a control system, as a

safety interlocks, or to count objects passing a point. A limit switch is an
electromechanical device that consists of an actuator mechanically
linked to a set of contacts. When an object comes into contact with the
actuator, the device operates the contacts to make or break an electrical
connection.

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Fig 16: Stepper Motor.

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Fig 17: Digital Level box for angle measuring.

Digital Level Box provides relative and absolute measurements as well

as zero setting to any position. With the LCD display, readings are more
convenient to read. Engineered to be compact and light makes it easy to
be carried and used. The measuring plane comes a disk magnet which
can be attached to the surface for steadier readings.

PORTABLE AND EASY TO USE

With small size 60mm*60mm*30mm, you could carry by hand easily.

 Easy-read large readout LCD display with backlight.

 Fast and accurate measurements
 Accuracy: 0.2 degrees
 Resolution: 0.1 degree
 Measuring range: 4*90degree
 Power source: 1*AAA battery (not included)
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Fig 18: Jiecang Linear Actuator.

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Fig 19: Janatics Filter Regulator Lubricator 1/2" (FRL).

Fig 20: Pilot Type 59 Spray Gun.

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Fig 21: 2 Pin, 4 Pin & 5 Pin Electrical metal connectors.

An electrical connector is an electro mechanical device used to
join electrical terminations and create an electrical circuit. Electrical
connectors consist of plugs (male ended) and jacks (female ended). The
connection may be temporary, as for portable equipment, require a tool
for assembly and removal, or serve as a permanent electrical joint
between two wires or devices. An adapter can be used to effectively
bring together dissimilar connectors.

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Fig 21: Actuator remotes and its control.

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