Precautions for ABB robot spraying work
ABB robot spraying operations must strictly follow safety regulations and operation procedures. The following are key points to note from five aspects: equipment characteristics, safety protection, operation norms, maintenance and emergency handling:
1. Equipment characteristics and selection are compatible
Model selection
Compact spraying: such as IRB 52, suitable for small and medium-sized parts, with a working range of 1.2-1.45 meters, supports inverted and inclined installation, has a small spray booth size, and is energy-saving and highly efficient.
High flexibility models: such as IRB 5510, equipped with hollow wrist technology to reduce pipeline wear, support 140° wrist rotation, and suitable for complex path spraying.
Heavy-duty applications: Models such as IRB 6640 can carry higher loads, but attention should be paid to their IP67 protection level and temperature control requirements (operating temperature 5-50℃).
Control system compatibility
IRC5P/OmniCore controller: The FlexPaint teaching device integrated with Ex explosion-proof certification supports RobView 5 monitoring software. The RobotWare Paint firmware needs to be updated regularly to ensure the accuracy of process control.
2. Safety protection requirements
Personal protective Equipment (PPE)
Operators must wear anti-static spray suits, gas masks (conforming to NIOSH standards), protective glasses, chemical protective gloves and safety shoes.
Non-explosion-proof electronic devices (such as mobile phones) are prohibited in explosion-proof areas. Intrinsically safe walkie-talkies must be used.
Environmental safety
Ventilation and explosion-proof: The spray booth must comply with ATEX/IECEx explosion-proof standards, and the ventilation volume should meet the MSDS requirements of the coating. The concentration of flammable gases should be regularly tested.
Grounding and static control: Workpieces, robots and spraying equipment must be reliably grounded. When using conductive coatings, an ion fan should be added.
3. Operating norms and procedures
Preparations before spraying
Equipment inspection: Verify the sealing performance of the color-changing valve, paint regulating valve, pump and hose, and test the atomization effect of the spray gun (sector width, flow rate).
Program calibration
The ABB Simple Programming System (SRP) or RobView is used for path teaching to ensure that the trajectory does not interfere with the workpiece.
Perform an empty run test to check whether the shaft movement speed and acceleration meet the requirements of the process card.
Spraying process monitoring
Real-time parameters: The spraying pressure (0.3-0.5MPa), flow rate (200-400ml/min), and atomization air pressure (0.2-0.3MPa) are monitored through RobView 5.
Quality spot check: Check the film thickness (dry film thickness 20-30μm) and uniformity (±5μm) every 30 minutes, and record the color difference value (ΔE≤1).
Safety operation taboos
It is prohibited to enter the working area during automatic spraying. If maintenance is needed, the robot must be stopped and the safety door locked.
Avoid spraying the spray gun into the air to prevent the coating atomized particles from depositing on the robot's joints.
4. Maintenance and care strategies
Daily maintenance
Cleaning: Immediately after the spraying is completed, clean the spray gun, color-changing valve and hose with solvent to prevent the coating from curing and clogging.
Lubrication: Apply grease (such as Mobilith SHC 220) monthly to the hollow wrist bearings of models like IRB 52.
Regular calibration
Accuracy calibration: Use a laser tracker to verify the robot's repeat positioning accuracy every quarter (IRB 52 should be ≤±0.5mm).
Flow calibration: Verify the flowmeter of the IPS system to ensure that the deviation of the paint supply from the set value is ≤2%.
Spare parts Management
Stock up on key spare parts (such as spray guns, sealing rings of color-changing valves, and filters), and regularly check the validity period of inventory (spare parts for solvent-based coatings need to be moisture-proof).
5. Emergency response procedures
Spray blockage or leakage
Immediately stop the robot, close the paint supply valve, and after putting on protective equipment, inspect the spray gun and hose.
Use special tools to clear the blockage and replace the leaking parts. It is strictly forbidden to operate under pressure.
Robot malfunction or alarm
Locate problems (such as shaft overload and communication interruption) through the fault log of the IRC5P controller, refer to the ABB maintenance manual or contact technical support.