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Abstract
Dry film thickness and appearance are the main quality improvements that can be achieved by an automated painting system in the manufacturing process. This study presents the spray coating process for aircraft parts using a gantry robot with an automated spray-painting gun to control the spray path, thus achieving the desired coating layer thickness. The experimental results show that the 3-gun atomization spray method, with high capacity airflow and outstanding atomization characteristics, poses the challenge of achieving an even thickness of the overlapping spray pattern from three separate guns, minimizing the paint material consumption and controlling the dry film thickness within the given specification and standard. The optimization was performed to control the spray path and material consumption with a 3-gun spray method to achieve the optimum setting for the spray nozzle to workpiece height to obtain the target thickness. The results show that replacing the manual process with the automated painting process can increase the speed by up to 30-40%, reduce the setup time and increase the capacity of the painting booth. The development of this system can achieve the desired thickness specification, increase productivity and provide safer, more effective and ergonomic working conditions.
Highlights
Aviation coatings, known as aircraft coatings or paintings, are broadly used in both commercial and military aviation industries ranging from military aircraft sector to the space sector and other flying vehicles
This study stated the overall process of parameter setting for an automated spray-painting gantry-robot system using a 3-gun atomization spray and using those settings to achieve the best height from a nozzle to a workpiece setting with an optimum overlapped area between the three guns to obtain the target thickness
The outcome demonstrated that the 3-gun atomization spray method with high capacity airflow and outstanding atomization characteristics system can achieve an even thickness of overlapping spray pattern dispersed from three separate guns, minimize the paint consumption and control the dry film thickness within the given specification and standard
Summary
Known as aircraft coatings or paintings, are broadly used in both commercial and military aviation industries ranging from military aircraft sector to the space sector and other flying vehicles. The coating process which uses materials has to ensure protection from corrosion, abrasion, erosion and more within the temperature changing environments and extreme weather conditions, (Coating.co.uk, n.d.). By the time, when an aircraft wing arrives at the manufacturing assembly line, similar to all other aircraft wing panels will be covered in a green protective coating. When the protective coating is removed, the paint is applied and the aircraft wings are likewise coated with a weather-resistant coating system. The walkways on aircraft wings are coated, this time with a non-slip coating for cargo floor panels and escape routes and payload floorboards which suggested in aerospace coatings by AkzolNobel’s Aviox paint and coating standard, (Aerospace Coatings, n.d.; Mike, 2012)
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