Search results

Automatic trajectory generation for spray painting is highly desirable for today’s automotive manufacturing. Generating paint gun trajectories for free‐form surfaces to satisfy paint thickness requirements is still highly challenging due to the complex geometry of free‐form surfaces. In this paper, a CAD‐guided paint gun trajectory generation system for free‐form surfaces has been developed. The system utilizes the CAD information of a free‐form surface to be painted and a paint gun model to generate a paint gun trajectory to satisfy the paint thickness requirements. A paint thickness verification method is also provided to verify the generated trajectories. The simulation results have shown that the trajectory generation system achieves satisfactory performance. This trajectory generation system can also be applied to generate trajectories for many other CAD‐guided robot trajectory planning applications.

Modern CAD systems facilitate the creation of any surface geometry imaginable, and complex surfaces for free-form grid shells are often represented by a set of Non-Uniform Rational B-Splines surface patches. But it remains an intractable issue how to generate high-quality grids on complex surfaces efficiently. To solve this issue, an automatic triangular mesh generation method is presented, based on bubble dynamics simulation and a modified Delaunay method.

A moderate amount of points are first distributed on a given surface. Next, by regarding the points as elastic bubbles with the same size and introducing the forces acting on bubbles, the motion control equations of bubbles are established. The equilibrium state of the bubble system is found by Verlet algorithm. Then, the Voronoi diagram on the surface is obtained by calculating the intersection between the surface and the three-dimensional (3D) Voronoi diagram of the centers of bubbles. Finally, a triangular mesh, Delaunay triangulation on the surface, is determined based on the dual change of the Voronoi diagram.

This method generates meshes on the surface directly, unlike mapping-based methods, avoiding the mapping distortion. Examples are given to demonstrate the successful execution of this method. The result also illustrates that this method is applicable to various surfaces in high automation level and resultant meshes are highly uniform and well-shaped.

Thus, this method provides the convenience for the geometry design of complex free-form grid structure.

This paper aims to present a new offline robot programming approach for automated trajectory generation on free-form surfaces targeted toward spray painting application.

In this paper, an incremental trajectory generation approach is developed where new paint passes are generated based on paint deposited on the surface as a result of previous paint passes. The trajectory is generated on real surfaces where optimal velocity is calculated using genetic algorithm considering parameters such as surface model, spray gun model, paint distribution model and task constraints.

The developed approach was implemented on various surfaces for different paint distribution patterns, and the simulation results reveal that the approach is flexible and efficient to handle variety in part geometry and paint distribution. From experimental validation and analysis of results thus obtained, the developed approach is highly promising compared to the existing methods.

The approach assumes that the computer-aided design (CAD) model of the surface is available and is limited to surjective surfaces in a structured environment where the spray gun characteristics and process parameters are known beforehand.

The problem of programming a robot manually is overcome by automatically generating a sub-optimal trajectory which can be easily transferred to an industrial robot for spray painting the surface.

This paper discusses a new approach for automated trajectory generation from CAD model. The experimental validation of the developed approach is successfully performed on a highly curved test surface, and obtained results are in agreement with the simulation results.

This paper aims to provide a series of new methods for projecting a three-dimensional (3D) object onto a free-form surface. The projection algorithms presented can be divided into three types, namely, orthogonal, perspective and parallel projection.

For parametric surfaces, the computing strategy of the algorithm is to obtain an approximate solution by using a geometric algorithm, then improve the accuracy of the approximate solution using the Newton–Raphson iteration. For perspective projection and parallel projection on an implicit surface, the strategy replaces Newton–Raphson iteration by multi-segment tracing. The implementation takes two mesh objects as an example of calculating an image projected onto parametric and implicit surfaces. Moreover, a comparison is made for orthogonal projections with Hu’s and Liu’s methods.

The results show that the new method can solve the 3D objects projection problem in an effective manner. For orthogonal projection, the time taken by the new method is substantially less than that required for Hu’s method. The new method is also more accurate and faster than Liu’s approach, particularly when the 3D object has a large number of points.

The algorithms presented in this paper can be applied in many industrial applications such as computer aided design, computer graphics and computer vision.

Focuses on the development and testing of software for reading and formatting digitized data and exporting it to rapid prototyping (RP). Research and development over two years has involved the implementation of special computer‐aided sculpting software that runs on UNIX workstations and which imports 3D polygonal mesh data in STL, OBJ and DXF formats, then re‐shapes it, much like the pushing and pulling on the surface of a rubber membrane. Specifying a wall thickness gives the model volume, prior to exporting an STL file. Describes how data has been imported form laser digitizing systems, had its shape changed and then how RP parts have been created from the model data.

The purpose of this paper is to present a new method for automated post machining process planning for a hybrid manufacturing process. The manufacturing process is expected to generate complex functional parts by taking advantage of free form surface creation from additive manufacturing and high-quality surface finishing from CNC milling.

The hybrid process starts with additive manufacturing to generate a near net shape part with pre-defined machining allowances on surfaces requiring high quality surface or tight tolerances, along with integrated fixture geometry. The next step is to conduct automated machining process planning to determine critical parameters such as setup angle, tool selection, depth, tool containment, and consequently, the NC code to machine the part.

This method is shown to be a feasible solution for rapidly creating functional parts. The tests have been conducted to validate the method developed in this paper.

This paper introduces a new automated post machining process planning method for integrating additive manufacturing with a rapid milling process.

The purpose of this paper is to establish a paint deposition pattern model applied to robotic air spray painting in order to achieve the accuracy and uniformity of paint film thickness on free‐form surface.

The paper opts for an exploratory study using the curvature circle method for air spray painting on free‐form surface to construct a spray gun model. First, a paint deposition pattern model of ellipse dual‐β distribution is fitted on the basic of experimental data from robotic air spray painting. Second, a spray gun model is proposed using the curvature circle method for air spray painting on free‐form surface. The theoretical result is coincident with the film thickness in verification experiment spraying a cylinder surface. The biggest error of the sample points between the theoretical and experimental results is less than 4 μm, thereby the correctness and effectiveness of the proposed model is validated.

The paper provides a specific theoretical and methodological support for the realization of process planning and simulation system in surface spray manufacturing. It will make the future developed system meet the actual processing requirement. At the same time, it is more representative.

The paper finds an approach to solve paint deposition pattern model suitable to free‐form surface. The present method can be applied to the complex reality of topological relation for actual workpiece surface to be painted.

To introduce an innovative method for the design of supporting elements to be applied to the free‐form components during the dimensional control.

This paper shows an innovative procedure based on reverse engineering and rapid prototyping techniques for the realization of fixtures fitting the geometry of free‐form elements. The application of the procedure have been made on a sheet metal free‐form element. After the design and manufacturing of the supporting elements, some uniformly distributed measurements have been made on the sheet metal component. A coordinate measuring machine (CMM) has been used in order to get dimensional information and to give the IT class location of the component.

The use of the CMMs for the dimensional control of the production elements requires the availability of an adequate supporting system above all if the control concerns free‐form components with complex forms. This influences considerably the final quality of the measurements mainly if the control concerns free‐form components with complex forms, not bound to classic geometric entities. The supporting systems commonly used foresee the utilization of standard elements (clamps, magnets, suction cups and plates and others) ideal for the parts with regular geometry but that can cause inconveniences if applied to free‐form elements and long times for the part supporting. The supporting elements of our paper fit to the geometry of free‐form component.

For the production of the supporting elements, the chosen technique has been the selective laser sintering with the use of the Pa‐Al powders (alumide). This material has a limited mechanical resistance such to guarantee a control up to 500 parts. For this reason, in a future research we would produce these fixtures using sintered metal materials.

The possibility to guarantee a correct dimensional control in the case of free form components using fixtures that fit to the geometry of free form components.

The paper shows an innovative procedure to get fixturing elements that fit to the geometry of free‐form component and provide stability and immobility to the component during the inspection phase.

The introduction of time compression technologies into the modern mechanical design process is now well established. Most major automotive and aerospace companies have invested, as have their Tier 1 suppliers. It has been identified that a bottleneck affecting all aspects of the cycle is the measurement process. In this paper we shall discuss potential benefits of adopting non‐contact techniques. In section 1 we discuss the need for rapid physical measurement within the context of the mechanical design process. The processes required for surface creation and inspection are discussed in Section 2 with regard to contact and non‐contact measurement. Section 3 reviews the operating principles of commercially available non‐contact systems. Finally Section 4 discusses practical issues relating to the implementation and use of non‐contact systems in the manufacturing environment.

This paper aims to develop an efficient surface‐plane intersection (SPI) algorithm for direct slicing of free‐form surfaces to be produced by layered manufacturing.

A semi‐analytical method for direct slicing has been formulated and tested on Bezier and B‐spline surfaces commonly used in CAD modeling. This method solves for the intersection points by a “root” finding procedure and establishes their connectivity, unlike the conventional “marching” procedures.

The proposed algorithm solves intersection contours between free form surfaces and planes. The solution procedure is efficient with respect to computational time and accuracy (feature detection) over some of the conventional SPI strategies. The method involves a global solution procedure in contention with the traditional methodologies which are generally spatially distinctive in approach.

Use of higher order terms in the representation of parametric surfaces makes the algorithm computationally intensive and time‐expensive.

This algorithm would be of practical use in the direct slicing of free form surfaces used in CAD modeling. Direct slicing methods solve for the actual intersection of surface and plane without resorting to “tessellation.” Reducing the computation time and detection of features within a given resolution is of primary importance for developing commercial rapid prototyping software, which is achieved in the present paper.

A novel method has been developed for SPI for use in direct slicing of CAD models. While a major proportion of the direct slicing strategies employ the “marching” procedure involving determination of “critical points,” the proposed method utilizes the evaluation of “roots” of a surface in a global manner to determine the intersection points with proper connectivity. Hence, it is effective in reducing the computation time and is simple but generic in approach. Although Bezier and B‐spline surfaces are used as the representative cases, the algorithm can be extended for any parametric surface for direct slicing.