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The bisection inverse search bow height control interpolation (BIS-BHCI) method for nonuniform rational B-splines (NURBS) curve is proposed to accomplish the serial robotic plasma cladding of planar complex curve coating with high precision.

A plasma–computer integrated cladding system is constructed based on a Motoman-UP6 serial robot and a plasma power. Based on the BIS-BHCI method, combining the serial robotic kinematics with the NURBS curve model, an offline plasma cladding software is developed for Motoman-UP6. Before plasma cladding, a planar NURBS curve coating is designed and defined and its BIS-BHCI is carried out with proper parameters. Then, the cladding programs are generated using the BIS-BHCI results and the robotic kinematics and inputted into the serial robotic controller. After that, the plasma cladding of the planar NURBS curve coating is implemented based on the Motoman-UP6 serial robot.

The simulation and plasma cladding for the NURBS curve coating shows that the BIS-BHCI method is feasible and effective. Plasma cladding of complex NURBS curve coating based on serial robot is feasible and effective.

The complex NURBS curve coating is prepared based on a serial robot platform for the first time. It provides a theoretical and technical basis for plasma cladding to produce surface coatings of industrial complex parts. With the increasing application of complex parts, the plasma cladding process of complex NURBS curve coatings has a broad application prospect.