Article(id=1195320602329387755, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1195320600727167098, articleNumber=null, orderNo=null, doi=10.19710/J.cnki.1003-8817.20240222, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1762916239577, onlineDateStr=2025-11-12, pubDate=1742400000000, pubDateStr=2025-03-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1762916239577, onlineIssueDateStr=2025-11-12, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1762916239577, creator=13701087609, updateTime=1762916239577, updator=13701087609, issue=Issue{id=1195320600727167098, tenantId=1146029695717560320, journalId=1189873562199433220, year='2025', volume='', issue='3', pageStart='1', pageEnd='72', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1762916239195, creator=13701087609, updateTime=1762916470865, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1195321572484485387, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1195320600727167098, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1195321572484485388, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1195320600727167098, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=30, endPage=39, ext={EN=ArticleExt(id=1195320602522325741, articleId=1195320602329387755, tenantId=1146029695717560320, journalId=1189873562199433220, language=EN, title=Application of Virtual Simulation in Automobile Spraying Process Commissioning, columnId=1190284220686766583, journalTitle=Automobile Technology & Material, columnName=Original article, runingTitle=null, highlight=null, articleAbstract=

To improve the rationality of automotive spray design, spraying simulation technology is introduced to dynamically analyze the commissioning process of spraying robots on the basis of traditional spraying technology, and the paint film thickness effect is evaluated visually for the spraying path and spraying parameters. The results show that the matching rate between simulation calculation of painting film thickness and painting workshop reaches 84%, the homogeneity of painting film thickness is improved by 15%. In addition, the wastage of paint is reduced, paint cost is reduced by 5%, and varnish cost is reduced by 11%.

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为提升产品喷涂设计的合理性,在传统喷涂技术的基础上,引入喷涂仿真技术对喷涂机器人调试过程进行动态分析,对喷涂路径及喷涂设定参数进行直观的膜厚效果评估,结果表明,喷涂膜厚仿真计算与现场实际匹配度可达84%,涂层的膜厚均一性最大提升约15%,同时降低了涂料的浪费量,色漆成本降低5%,清漆成本降低11%。

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魏雪(1984—),女,高级工程师,硕士学位,研究方向为汽车涂装防腐。

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魏雪(1984—),女,高级工程师,硕士学位,研究方向为汽车涂装防腐。

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序号 流量
/mL·min-1
空气压力/kPa 转速
/r·min-1
高压
/kV
枪距
/mm
枪速
/mm·s-1
1 260 200 30 000 70 200 200
2 400 200 30 000 70 200 200
3 260 310 30 000 70 200 200
4 400 310 30 000 70 200 200
5 260 200 50 000 70 200 200
6 400 200 50 000 70 200 200
7 260 310 50 000 70 200 200
8 400 310 50 000 70 200 200
9 260 260 40 000 70 200 200
10 400 260 40 000 70 200 200
11 330 200 40 000 70 200 200
12 330 310 40 000 70 200 200
13 330 260 30 000 70 200 200
14 330 260 50 000 70 200 200
15 330 260 40 000 70 200 200
), ArticleFig(id=1195336136726986792, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1195320602329387755, language=CN, label=表1, caption=

机器人喷涂设置参数

, figureFileSmall=null, figureFileBig=null, tableContent=
序号 流量
/mL·min-1
空气压力/kPa 转速
/r·min-1
高压
/kV
枪距
/mm
枪速
/mm·s-1
1 260 200 30 000 70 200 200
2 400 200 30 000 70 200 200
3 260 310 30 000 70 200 200
4 400 310 30 000 70 200 200
5 260 200 50 000 70 200 200
6 400 200 50 000 70 200 200
7 260 310 50 000 70 200 200
8 400 310 50 000 70 200 200
9 260 260 40 000 70 200 200
10 400 260 40 000 70 200 200
11 330 200 40 000 70 200 200
12 330 310 40 000 70 200 200
13 330 260 30 000 70 200 200
14 330 260 50 000 70 200 200
15 330 260 40 000 70 200 200
), ArticleFig(id=1195336136819261481, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1195320602329387755, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
项目 膜厚范围/μm 满足范围点数量
(测量点共92点)/个
合格率/%
车门 后侧围 侧围上端
调试前 ±2 28 17 19 69.57
±1 12 11 12 38.04
调试后 ±2 34 24 22 86.96
±1 27 14 15 60.87
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调试前、后合格率对比

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项目 膜厚范围/μm 满足范围点数量
(测量点共92点)/个
合格率/%
车门 后侧围 侧围上端
调试前 ±2 28 17 19 69.57
±1 12 11 12 38.04
调试后 ±2 34 24 22 86.96
±1 27 14 15 60.87
), ArticleFig(id=1195336136957673515, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1195320602329387755, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
涂层 BC01 BC02 CC
机器人消耗 R11 R12 R13 R14 合计 R11 R12 R13 R14 合计 R11 R12 合计
调试前 462 395 310 231 1 398 215 140 321 227 903 407 454 861
调试后 448 371 300 222 1 341 196 138 286 223 843 347 418 744
差值 14 24 10 9 57 19 2 35 4 60 60 36 96
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机器人涂料消耗对比统计 mL

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涂层 BC01 BC02 CC
机器人消耗 R11 R12 R13 R14 合计 R11 R12 R13 R14 合计 R11 R12 合计
调试前 462 395 310 231 1 398 215 140 321 227 903 407 454 861
调试后 448 371 300 222 1 341 196 138 286 223 843 347 418 744
差值 14 24 10 9 57 19 2 35 4 60 60 36 96
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虚拟仿真在汽车喷涂工艺调试中的应用
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魏雪 , 王化娥 , 郑召健 , 华冰 , 刘艺
汽车工艺与材料 | 生产现场 2025,(3): 30-39
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汽车工艺与材料 | 生产现场 2025, (3): 30-39
虚拟仿真在汽车喷涂工艺调试中的应用
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魏雪, 王化娥, 郑召健, 华冰, 刘艺
作者信息
  • 中国重汽集团济南动力有限公司, 济南 250000
  • 魏雪(1984—),女,高级工程师,硕士学位,研究方向为汽车涂装防腐。

Application of Virtual Simulation in Automobile Spraying Process Commissioning
Xue Wei, Hua’e Wang, Zhaojian Zheng, Bing Hua, Yi Liu
Affiliations
  • Sinotruk Jinan Power Co., Ltd., Jinan 250000
出版时间: 2025-03-20 doi: 10.19710/J.cnki.1003-8817.20240222
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为提升产品喷涂设计的合理性,在传统喷涂技术的基础上,引入喷涂仿真技术对喷涂机器人调试过程进行动态分析,对喷涂路径及喷涂设定参数进行直观的膜厚效果评估,结果表明,喷涂膜厚仿真计算与现场实际匹配度可达84%,涂层的膜厚均一性最大提升约15%,同时降低了涂料的浪费量,色漆成本降低5%,清漆成本降低11%。

机器人  /  喷涂  /  仿真  /  调试

To improve the rationality of automotive spray design, spraying simulation technology is introduced to dynamically analyze the commissioning process of spraying robots on the basis of traditional spraying technology, and the paint film thickness effect is evaluated visually for the spraying path and spraying parameters. The results show that the matching rate between simulation calculation of painting film thickness and painting workshop reaches 84%, the homogeneity of painting film thickness is improved by 15%. In addition, the wastage of paint is reduced, paint cost is reduced by 5%, and varnish cost is reduced by 11%.

Robot  /  Spraying  /  Simulation  /  Commissioning
魏雪, 王化娥, 郑召健, 华冰, 刘艺. 虚拟仿真在汽车喷涂工艺调试中的应用. 汽车工艺与材料, 2025 , (3) : 30 -39 . DOI: 10.19710/J.cnki.1003-8817.20240222
Xue Wei, Hua’e Wang, Zhaojian Zheng, Bing Hua, Yi Liu. Application of Virtual Simulation in Automobile Spraying Process Commissioning[J]. Automobile Technology & Material, 2025 , (3) : 30 -39 . DOI: 10.19710/J.cnki.1003-8817.20240222
机器人涂装喷涂工艺在汽车、航天航空、船舶等众多领域均有重要应用,不同产品所需的喷涂工艺、涂料类别和喷涂设备不同。当前市场竞争越发激烈,急需在喷涂技术上有所突破,以应对产品质量要求的日渐提高、生产效率及成本控制的精益求精以及产品更新周期的大幅缩短等。
离线编程涂装虚拟制造方法能提高喷涂路径设计及机器人调试效率,但由于缺乏油漆验证和实用的膜厚模拟工具,无法预测喷涂路径的合理性、喷涂可能存在的质量风险、喷涂环境与油漆控制参数对涂层的影响。因此在喷涂调试及生产过程中,需要缓慢且高昂的试错过程,不仅提高了成本,还影响产品质量及生产过程的稳定。
喷涂仿真虚拟工具能够模拟机器人喷涂路径、涂料设定参数、风场及静电场对喷涂膜厚的影响,能够利用虚拟原型代替实物原型对喷涂效果进行评估,降低了调试成本;能够预测喷涂的质量风险,减少了不可预见的成本,并在产品早期制定解决方案,有效缩短了产品更新周期,提高了产品质量和竞争力。
喷涂工艺按喷涂工具分为喷枪喷涂与旋杯喷涂,按加电方式分为静电喷涂与非静电喷涂,按涂料类型分为高固含涂料、粉末涂料等。本文以常用的旋杯静电喷涂来说明喷涂仿真的基本原理。
IPS Virtual Paint Spray软件是使用浸入网格边界法[1]进行喷涂膜厚模拟,依赖计算流体动力学(Computational Fluid Dynamics,CFD)模拟气流和电耦合场,在气流、电子磁场环境下,将油漆分解成液滴,跟踪这些液滴直到其挥发或撞击到表面,利用模拟液滴碰撞来估算漆膜厚度。
喷涂控制参数有油漆流量、转速、成型空气压力等,在空气和电场中将体现为碰撞速度和液滴体积的影响。当液滴撞击表面时,可能散开或飞溅,具体受液滴大小、冲击速度和角度、油漆粘度以及表面粗糙度的影响。
油漆通过高压喷出,在高压空气及旋杯高速旋转的作用下雾化,并通过油漆的吐出量、高压空气及转速的参数化控制实现喷涂雾化控制。
外加电的喷涂雾化器电极在放电时,强大的电势会电离气体,在较小的电离区外大部分是负离子,负离子会向阳极(目标接地)偏移运动,原因是负离子的速度远大于油漆颗粒的速度,涂料被离子轰击而带电。如果采用内加电的喷涂器,可假设离开的液滴带有电荷,液滴电荷与液滴面积成正比。
综上,喷涂模拟求解器主要由3个部分组成:气流求解器、静电求解器和液滴求解器。进行耦合求解流场、电场和液滴运动,气流通过动量传递和阻力与液滴进行耦合,电场通过液滴空间电荷密度和静电力与液滴进行耦合,最后,气流与电场通过液滴进行耦合[1-2],如图1所示。
本文求解器由Navier-Stokes求解器和IBOFlow求解器组成,可有效地求解气液两相流,模拟跟踪喷涂过程中的气流、液体及电场下的液滴粒子,直至其撞击表面或消散,并求解出涂层厚度。
不可压缩流体采用Navier-Stokes方程模拟:
$\nabla \cdot \stackrel{-}{u}=0$
涂装喷涂仿真实现算法为:
${\rho }_{f}\frac{\partial \stackrel{-}{u}}{\partial t}+{\rho }_{f}\stackrel{-}{u}\cdot \nabla \stackrel{-}{u}=-\nabla p+\mu {\nabla }^{2}\stackrel{-}{u}+\stackrel{-}{s}$
式中:$\stackrel{-}{u}$为流体速度,${\rho }_{{}_{f}}$为流体密度,p为流体压力,µ为流体动力黏度,$\stackrel{-}{s}$为漆滴出口边界条件。
在算法中,流体速度设定为侵入边界条件的局部速度。
对于带电荷的雾化器,雾化器与接地端(目标)产生电场的电势差值[3-4]为:
${\nabla }^{2}\varphi =-\frac{\rho }{\epsilon }$
$\stackrel{-}{E}=-\nabla \varphi $
式中:ϕ为电势,ε为电容率,ρ为空间电荷密度,$\stackrel{-}{E}$为电场。
涂料液滴被视为拉格朗日粒子[5],通过颗粒非恒定运动(Brownian Motion in Bulk,BBO)方程可得到液滴的重力/浮力、阻力、静电力的运动:
${\rho }_{p}\frac{d{\stackrel{-}{u}}_{p}}{dt}=({\rho }_{p}-{\rho }_{f})\stackrel{-}{g}-{\stackrel{-}{u}}_{r}\left|{\stackrel{-}{u}}_{r}\right|{C}_{d}\frac{{\rho }_{f}}{{\rho }_{p}}\frac{{m}_{p}}{2{r}_{p}}+\stackrel{-}{E}{q}_{p}$
式中:${\rho }_{p}$为液滴的密度,${\stackrel{-}{u}}_{p}$为液滴的速度,${\stackrel{-}{u}}_{r}$为相对速度,Cd为阻力系数,mp为液滴质量,rp为液滴半径,qp为液滴电荷。
其中,阻力系数Cd可评估为:
${C}_{d}=24\frac{1+0.15{R}_{ep}^{  0.687}}{{R}_{ep}},{R}_{ep}=\frac{2{r}_{p}\left|{\stackrel{-}{u}}_{r}\right|{p}_{f}}{\mu }$
式中:Rep为液滴瞬时雷诺数。
IBOFlow求解器[6]基于有限体积离散化,采用浸入边界方法模拟雾化器到目标表面的流场行为,可细化和粗化笛卡尔树网格,如图2所示。
通过将被涂覆曲面分割成适当的小块,求解计算每小块的膜厚,数模网格为四边形或三角形,可将此膜厚插入几何顶点,获得平滑的膜厚云图效果。
利用仿真软件模拟油漆喷涂膜厚的流程如下:
a. 建立数据库:通过试验测量不同涂料、不同喷涂参数等条件下油漆粒子的状态,创建雾化器喷涂数据库,即刷子表;
b. 数据准备:完成零件数模及喷涂路径输入、喷涂参数设定、环境边界条件设置;
c. 膜厚仿真:进行喷涂膜厚仿真计算;
d. 结果输出:根据膜厚云图进行结果后处理及风险分析。
喷涂环境及工艺较为复杂,雾化器每秒喷出数十亿滴涂料穿过紊流和电场,直到附着于目标表面或成为废物被浪费。要模拟每个油漆粒子在喷涂过程中的运动状态,需要考虑多边条件的影响,如雾化器的吐出量、旋杯的转速、成型空气的压力等。不同条件下油漆粒子会以不同的速度、角度撞击被涂覆物表面。
同时,还需要确定油漆粒子的带电量,电荷离子密度决定了撞击油漆颗粒的离子数量,电场的强度决定了作用在油漆粒子上的静电力。
油漆从旋杯边缘如丝状注射到空气中并逐渐破损雾化,喷涂仿真截取旋杯下方一定距离的区域作为仿真输入的边界条件,不考虑旋杯附近区域的复杂的物理行为,原因是喷雾为稀释远离,附近区的液滴与离散态液滴之间的相互作用可忽略。采用激光多普勒测速仪(Laser Doppler velocimeter,LDA)和粒子图像测速仪(Particle image velocimeter,PIV)测量液滴的尺寸、雾化器附近的空气和液滴速度[7],如图3所示。
喷涂前应确认以下条件是否满足要求:
a. 确定涂料的施工性能,如黏度、密度、固含等;
b. 机器人喷涂设定适当的喷涂流量、空气压力、旋杯转速及电压,如表1所示。
为更好地捕捉漆雾粒子的运动状态,使用风速仪和测速仪测量漆雾速度,通过激光衍射测量粒子的分布,最后可将试验数据应用到喷涂仿真的基础数据库中。
a. 激光多普勒风速仪:如图4所示,假定流场中液滴与流体的速度相同,当两束激光射向流体区域时,由于液滴对激光的散射作用,产生多普勒效应,从而测得液滴的速度,可获取单点的三维速度,如图5所示。
b. 粒子图像测速仪:如图6所示,假定流场中液滴与流体的速度相同,使用高速摄像头获取粒子的运动行为,绘制平面3D速度矢量,从而获得聚焦位置的速度矢量场。
c. 油漆雾化粒径尺寸分布:液滴的尺寸会影响激光的散射角,入射光在通过不同粒径的液滴时会呈现不同的散射角度,如图7所示。
d. 采用激光衍射可获取距离旋杯一定距离的粒径分布情况[8],如图8所示。
雾化器放电针与工件之间形成一个高压电晕放电电场,涂料液滴由旋杯喷出经过放电区时,携带了大量电子,成为带负电的液滴,在静电场的作用下吸附到工件上。液滴的带电量和电场强度会影响喷涂效果。
在雾化器下放置一个大平板,将电流密度计固定在上面,测量不同转角下的电流密度情况,如果允许可测量不同高度下电流[9-10],如图9所示。
喷板试验的目的是收集油漆在不同喷涂参数下的雾幅及膜厚分布,在雾幅一定的情况下,涂料上膜与油漆流量通常呈线性关系。本文采用现场机器人、雾化器和涂料,选择实际使用的喷涂参数进行喷涂试验。
图10图11所示,将喷涂试板水平或垂直放置并接地,设定适当的机器人喷涂速度及距离进行喷涂测试,喷涂结束后按工艺流程静置后烘烤,最终测量喷涂试板涂层厚度。
根据试验得到的测试数据创建刷子表,需分别定义气流速度、注射区域、油漆运动速度、油漆属性,并与实测膜厚进行匹配校正。
a. 雾化器空气速度场:如图12所示,定义注射区偏置距离、半径范围、速度大小和方向,并根据仿真度场与实际值的偏差进行微调。
b. 粒径分布函数:对测得的粒径分布数据进行拟合,模拟粒径空间动态分布[8],如图13所示。
c. 雾化涂料运动速度:根据喷幅情况定义注射区域,如液滴速度大小、油漆吐出量及边界位置等,如图14所示。
d. 油漆性能设置:油漆的密度、固体份及带电量作为其基础属性进行设置,如图15所示。
e. 喷涂仿真膜厚校正:根据设置的刷子参数进行喷涂仿真,如图16所示,与实测值进行校准,校正情况如图17所示。
数据准备为喷涂仿真的基础条件,如数模、喷涂路径及喷涂刷子表等。零件数模提供被涂覆物的几何结构,而喷涂路径通过坐标点与时间指定了雾化器在某一时刻的位置及喷涂角度,路径中的刷子编号可作为喷涂参数的控制点;喷涂刷子表中含有对应刷子编号的喷涂参数,可通过调控喷涂过程参数调控膜厚。
根据实物在CATIA中创建三维模型,将数模作为IPS Virtual Paint Spray喷涂仿真计算数模的输入。
图18所示,喷涂轨迹中含有机器人的点位空间坐标信息、刷子表分区信息、喷涂速度信息等。
设定刷子表的喷涂参数,主要包含雾化器的吐出量、成型空气、转速、电压等,如图19所示。
a. 风场设定:为防止漆雾飞溅以及便于废气回收,涂装喷漆室通常设有垂直向下的风场,会影响喷涂过程中油漆粒子的运动,因此,需要设定合理的风场风速和风场风压,如图20所示。
b. 零件参数设定:涂装工艺中喷涂零件的运动不同,汽车涂装分为连续式和间歇式,部分零部件如轮毂零件需要旋转喷涂,因此,需要设定零件运动轨迹。
不同材质的零件或不同工艺的零件所需的喷涂电压不同,常见的为非静电喷涂的绝缘及静电喷涂的接地,如图21所示。
IPS Spray提供了2种模式进行膜厚仿真:镜像模式及全耦合模式。
a. 在镜像模式中,风场、力场、磁场等不参与计算,仅考虑喷涂件造型结构,根据喷涂枪速、枪距、流量等计算膜厚,可快速完成仿真计算及结果分析,用于高效预调试喷涂参数及喷涂轨迹。
b. 全耦合模式可模拟喷涂过程中液滴的运动状态,能耦合求解流体运动的风场、力场、磁场,还可体现复杂型面与边缘效应对喷涂膜厚的影响,仿真运行精度较高,与现场实际匹配度高。
提交膜厚仿真求解计算界面如图22所示。
完成仿真计算后会获得膜厚仿真结果,膜厚云图能直观展现膜厚分布,还可对各部分进行膜厚打点测量,便于精准分析,以解决实际喷涂中的问题或提供问题解决方向。
在产品研发阶段,由于传统喷涂可行性缺乏评估手段,工程师仅能根据经验判断,存在风险评估不足或过渡解析等问题。
通过开展喷涂仿真在产品设计阶段的工程同步分析,可结合产品仿真膜厚结果对产品设计提出有效的整改意见,减少因设计带来的喷涂缺陷并有效控制生产成本。
通过分析及评估喷涂膜厚仿真结果,可提前发现轨迹设计中的不足,如枪距、喷涂折返距离等对喷涂重叠率(重叠率越低,涂层的均一性越差)的影响,不同的刷子表分区对喷涂效果的影响以及边缘控制效果等。通过喷涂仿真完成对喷涂轨迹的优化,将大幅提高喷涂调试效率。
喷涂的代表性缺陷有缺漆与流挂,均为膜厚控制失调,超出工艺范围出现的缺陷,通常伴随其他缺陷一同出现,如膜厚偏低的缺漆,可能表现为外观质量差、橘皮、露底、遮盖不良等;而膜厚偏高的过喷涂除造成流挂,还可能表现为针孔、痱子、流痕等,这些缺陷不仅影响产品质量,还会提高产品返工率,提高制造成本,影响生产效率。
通过仿真分析能提前发现问题并规避风险,提高了喷涂调试的效果和效率。
为达到漆面所要求的效果,涂装往往需要多层喷涂,目前,汽车行业常见的喷涂工艺有3C1B、3C2B、B1B2等,不同的喷涂工艺均需尽可能保证涂层厚度一致,有利于保证产品的外观质量和生产过程的稳定性,并适应设备的控制偏差。
提高膜厚的均一度即将膜厚控制在较小的波动范围内,不仅有利于控制质量,还有利于控制成本。因此,油漆喷涂膜厚仿真能预测膜厚,并通过不断优化喷涂参数或喷涂路径等提高产品的膜厚均一性。
在轨迹评估中进行轨迹的合理性分析,以设计出高质量的机器人喷涂轨迹。
轨迹评估方法:雾化器采取一组喷涂参数进行仿真,部分区域可能会由于喷涂边缘效应、喷涂过度重叠或喷涂不足等原因,其膜厚显示出现明显异常,膜厚偏高(偏红)的区域为易上膜区域或轨迹重叠较高区域,膜厚偏低(偏蓝)的区域则为重叠率较低的区域,如图23所示。
仿真结果分析可提供喷涂调试的优化方向,常用的调试手段如下:
a. 优化喷涂轨迹的折返距离或喷涂距离;
b. 局部轨迹调整喷涂角度或喷涂速度;
c. 喷涂轨迹针对特殊区域进行刷子分区,便于后期控制喷涂参数;
d. 不同区域根据重叠率设定相应的喷涂参数,以提高膜厚的均一性。
根据轨迹评估结果,识别出喷涂风险区域,对各区域进行轨迹点位置或角度调整,并反复进行轨迹评估直至喷涂轨迹满足如下要求:
a.喷涂轨迹满足生产节拍要求;
b.喷涂轨迹连贯通顺,机器人动作无异常;
c.喷涂轨迹重叠率设计合理,轨迹无严重重叠高膜厚区域和喷涂不良区域。
最后对喷涂轨迹进行详细的刷子分区优化调整,便于后续进行高精度的膜厚调试,如图24所示,优化后的喷涂轨迹设置了约50组控制参数。
若优化喷涂轨迹是涂层膜厚均一性调试[11-15]的前提,喷涂参数的调试则为膜厚调试的最终手段,通过虚拟喷涂仿真可调试喷涂参数,使涂层满足膜厚控制要求,且较高的均一性可提高涂层的外观质量,减少生产制造缺陷,降低生产成本。
通过调试喷涂参数的流量、空气成型、转速等,将最终优化喷涂参数进行现场应用,如图25所示。
图26所示,为确保仿真刷子数据库的准确性,对仿真结果与实车单层膜厚进行膜厚对比,本文所展示的膜厚数值均为仿真结果与目标值的差值,而非实际数值。
a. 由图27膜厚趋势对比分析可知,仿真与实测膜厚趋势基本一致。
b. 膜厚匹配度分析:仿真与实测膜厚偏差在10%以内的测量点数量与测量总数的占比为:
$r=\frac{n}{N}\times 100 \%$
式中:r为匹配度,n为满足偏差的测量点数量,N为膜厚测量总数。
在此项目中,10%的膜厚偏差仿真匹配度为84%,精准度较高。
图28表2为调试前、后膜厚数据对比,调试后膜厚差值范围为±2 μm的合格率由69%提升至86%,膜厚差值范围为±1 μm的合格率由38%提升至60%,更多的膜厚集中在中心控制区域,膜厚的整体波动范围更小,此时涂层膜厚对生产的兼容性更好,不易出现质量缺陷。
通过机器人流量监控统计涂料消耗,对比调试前、后的消耗差异,如表3所示,色漆机器人涂料节约4%~6%其中,BC01整车降代4%,BC02整车降代6%,清漆可节约11%。
汽车喷涂涂层调试采用虚拟仿真手段,通过膜厚的可视化展现,对机器人轨迹、喷涂参数进行产前调试,大幅缩短了现场实车喷涂周期;同时,通过评估车辆喷涂风险,提前发现或规避设计缺陷,减少现场试错调试。通过研究喷涂仿真技术,所得结论如下:
a.喷涂膜厚仿真计算与现场实际匹配度较高,可达84%;
b.通过仿真技术对车辆进行局部高精细的膜厚调试,极大提升了涂层的膜厚均一性,最大约提升15%;
c.通过对机器人吐出量的精准控制,降低了涂料的浪费量,色漆成本降低5%,清漆成本降低11%;
d.通过对喷涂仿真技术的研究,建立了喷涂数据库,完善了工艺调试体系。
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doi: 10.19710/J.cnki.1003-8817.20240222
  • 首发时间:2025-11-12
  • 出版时间:2025-03-20
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    中国重汽集团济南动力有限公司, 济南 250000
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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