How does a programming-free automatic spraying machine identify workpiece contours and spray paths?
Publish Time: 2025-09-02
How a programming-free automatic spraying machine identifies workpiece contours and spray paths is the core difference between it and traditional spraying equipment. It no longer relies on operators to manually input coordinates or program complex motion programs. Instead, it integrates a perception system and intelligent algorithms to autonomously identify workpieces and generate spray strategies. This capability is achieved by combining machine vision, sensor technology, and adaptive control logic, enabling the machine to "understand" the workpiece and plan an efficient and uniform spraying trajectory accordingly.The recognition process typically begins with a vision-guided system. Equipped with a high-resolution industrial camera or 3D scanner, the system immediately initiates image acquisition when the workpiece is placed in the spraying area. The camera captures the workpiece's external features from one or more angles, generating 2D or 3D point cloud data. This data is analyzed by image processing algorithms to extract the workpiece's edges, curved surfaces, hole locations, and critical contours. For regular geometric shapes, the system quickly matches pre-existing templates. For irregular-shaped parts, feature recognition and boundary detection are used to construct a spray path framework.Some high-end models use laser profile scanning technology, which precisely reproduces the object's three-dimensional shape by emitting a laser line and capturing its deformation on the workpiece surface. This non-contact measurement method is unaffected by ambient light and can capture subtle structures such as grooves, corners, and areas with varying curvatures, ensuring comprehensive spray coverage. After scanning, the system automatically generates a virtual envelope surrounding the workpiece and uses this to plan the spray gun's trajectory, maintaining a constant distance between the nozzle and the workpiece surface to avoid dripping caused by close proximity or uneven atomization caused by distance.During the path planning phase, the device's built-in intelligent algorithm automatically sets spray parameters based on the recognition results. The system determines the workpiece's material, surface roughness, and coating requirements, and, based on the spray gun's atomization characteristics, determines the scanning speed, oscillation frequency, paint delivery volume, and overlap ratio. For flat surfaces, parallel reciprocating scanning is used; for curved surfaces or edges, the spray gun's angle and motion profile are adjusted to ensure uniform paint adhesion. The entire process requires no manual intervention; the operator simply places the workpiece and starts the machine, and the system handles the rest.To enhance adaptability, some program-free sprayers have incorporated template learning. When processing a new workpiece for the first time, the operator manually guides the spray gun to perform a demonstration spraying. The system then records the motion trajectory and saves it as a template. Subsequently, when encountering the same or similar workpieces, the system automatically calls upon this template and makes minor adjustments, significantly reducing commissioning time. This "teach-and-use" model reduces the required operator skills, enabling even ordinary workers to quickly master the system.The device also features dynamic compensation capabilities. During the spraying process, if the workpiece deviates slightly or deforms, the vision system continuously monitors its positional changes and adjusts the spray gun path in real time to ensure the trajectory adheres to the actual contour. This closed-loop control mechanism enhances spraying robustness and accommodates common positioning errors in production sites.Ultimately, the programming-free automatic spraying machine transforms complex programming tasks into simple placement actions through a closed-loop process of "perception-analysis-decision-execution." It is not just the automation of a robotic arm; it is the embodiment of an intelligent system. In high-variety, small-batch production scenarios such as furniture, hardware, and plastic products, this intelligent recognition capability that does not require programming has significantly improved painting efficiency and consistency, reduced dependence on professional technicians, and promoted spraying operations towards true "fool-proof" automation.
