Research and realization of assistant off-line programming system for thermal spraying Chaoyue Chen To cite this version: Chaoyue Chen. Research and realization of assistant off-line programming system for thermal spraying. Automatic. Université de Technologie de Belfort-Montbeliard, 2016. English. NNT : 2016BELF0303. tel-01872036 HAL Id: tel-01872036 https://tel.archives-ouvertes.fr/tel-01872036 Submitted on 11 Sep 2018 HAL is a multi-disciplinary open access L’archive ouverte pluridisciplinaire HAL, est archive for the deposit and dissemination of sci- destinée au dépôt et à la diffusion de documents entific research documents, whether they are pub- scientifiques de niveau recherche, publiés ou non, lished or not. The documents may come from émanant des établissements d’enseignement et de teaching and research institutions in France or recherche français ou étrangers, des laboratoires abroad, or from public or private research centers. publics ou privés. Research and realization of assistant off-line programming system for thermal spraying Chaoyue CHEN N° d’ordre :303 Année : 2016 Université de technologie de Belfort-Montbéliard Ecole doctorale Sciences physiques pour l’Ingénieur et Microtechniques THESE Présentée pour obtenir le grade de Docteur de l’Université de Technologie de Belfort-Montbéliard en Sciences pour l’Ingénieur Research and realization of assistant off-line programming system for thermal spraying Soutenue publiquement le 16 décembre 2016 Chaoyue CHEN Rapporteurs Madame Christine PRELLE, Professeur des Universités, Université de Technologie de Compiègne Monsieur Vincent GUIPONT, Chercheur, HDR, MINES ParisTech Examinateurs Monsieur. Thierry BARRIERE, Professeur des Universités, FEMTO-ST Monsieur. Philippe CHARLES, Product Manager, ABB France Monsieur. Sihao DENG, Maître de Conférences-HDR, Université de Technologie de Belfort- Montbéliard Monsieur. Hanlin LIAO, Professeur des Universités, Université de Technologie de Belfort- Montbéliard I II Acknowledgement As this thesis is mainly done in the laboratory of IRTES - LERMPS, and supported by China Scholarship Council (CSC) in the framework of UT-INSA (2013), my thanks first go to all the collaborating parties which made this work possible at all. So, I want to thank the CSC to give me the chance to study abroad and broaden my vision, and as well as Mrs. Langlade CECILE, the director of laboratory LERMPS, to give me the opportunity to continue my study in the laboratory LERMPS. Firstly, my gratitude goes to the members of defence jury for their efforts in examining the work of thesis. In particular, I’m very thankful for Mrs. Christine PRELLE and Mr. Vincent GUIPONT to take their time to be the reviewers and help me improve the thesis. Besides, I feel honoured to have Mr. Thierry BARRIERE and Philippe CHARLES to be present as the jury members of the thesis defence session. Secondly, I would express my greatest gratitude to my thesis supervisors Dr. Sihao DENG and Prof. Hanlin LIAO, who have been extremely supportive along this journey of scientific research. It is their patience and guidance that lead me to the fields of thermal spray and robotics, with which I was not familiar at the beginning of my thesis. The vast knowledge in the fields of materials science and automation and clear thinking owed by Dr. Sihao DENG and Prof. Hanlin LIAO can always give me surprising inspiration during the PhD period. I would also thank Dr. Sihao DENG to give me the chance to be a temporary teacher, which helps me practice my French and enhance my understanding in programming skills. Except for the academic life, I also want to appreciate Dr. Sihao DENG and his wife Mrs. Yunfang GUI, Prof. Hanlin LIAO and his wife Mrs Hui WANG to help me adapt to the life in France and give me the consideration and endless concerns that let me feel at home. Thirdly, my thanks go to the colleagues in our laboratory who gave me countless help during my doctoral research and daily life in France. They are: Jean-Baptiste DEVILLERS, Emilie AUBIGNAT, Xinkun SUO, Taikai LIU, Baicheng ZHANG, Min YU, Xiaohua FENG, Jiangwei LIU, Duo YI, Amal Masmoudi, Nan KANG, Chunjie HUANG, Zexin YU, Xingcheng YAN, et al. Especially, I want to thank my good friends Shuo YIN, Yangzhou MA, Zhao ZHANG and Yingchun XIE for the academic cooperation and the scientific discussion, which broadens my vision and give me the inspiration. Most importantly, I would like to thank my girlfriend Hui SHANG. Her support, encouragement, consideration and unwavering love help me achieve the PhD diploma. Finally, I owe to my parents and my family at the moment, who have been the ones standing firmly behind my back. As always, during my study in France, they have been giving me wise advice and are always helping me to be a better person. My endless thoughts go to my grandmother who unfortunately passed away during my study in France. III IV Abstract The offline programming technology provides the possibility to generate complex robot trajectories in thermal spray process. In the laboratory of LERMPS, an add-in software called “Thermal Spray Toolkit” (T.S.T.) has been developed to assist the offline programming in the field of thermal spray. However, efforts are still expected to improve the functionality of this software. The aim of this study is to improve the application of offline programming technology in the thermal spray process. According to the procedure of the offline programming in thermal spray, the work of this thesis consists of three parts. Firstly, efforts have been dedicated to improve the module “PathKit” in T.S.T., which aim to improve the functionality of trajectory generation. The algorithm of trajectory generation for the curved substrate surface was improved to maintain a constant scan step. A novel Archimedean spiral trajectory was developed for damage component recovery application by cold spray. The experiment of an Al5056 coating depositing on a manually manufactured workpiece with a crater defect was carried out to validate the effects of spiral trajectory with adapted nozzle speed. Secondly, numerical models were developed to simulate the coating thickness distribution in 2D and 3D, and then integrated in the RobotStudio™ as an individual module named “ProfileKit”. In the “ProfileKit 2D”, it is able to evaluate the effects of operating parameters on coating profile and optimize the parameters. In the “ProfileKit 3D”, coating thickness distribution can be simulated based on the nozzle trajectory and robot kinematics data. The functionalities were validated by the trapezoid cold sprayed coating. At last, kinematic analysis was used to provide the optimization methods for a better robot performance in thermal spraying. In order to better evaluate the robot performance, an overall parameter (OP) that is the weighted mean of standard deviation of joint speed, was introduced to measure the complexity of a robot trajectory. Afterwards, the optimal nozzle mounting method as well as the optimal workpiece placement were investigated by the kinematic analysis and the overall parameter. The result shows that the kinematic optimization can effectively improve the robot performance to maintain the predefined speed. Key words: Thermal spray, offline programming, robot trajectory, robot kinematics, cold spray, coating thickness, damage repair V Résumé La technologie de programmation hors-ligne permet de façon générale la génération de trajectoires complexes. Dans le laboratoire IRTES - LERMPS, spécialisé dans les activités de la projection thermique, une extension logicielle appelée « Thermal Spray Toolkit » (T.S.T.) a été développée pour assister la programmation hors-ligne dans ce domaine spécifique. Cependant, des efforts sont encore attendus pour améliorer sa fonctionnalité. C’est pourquoi, l’objectif de cette thèse vise à améliorer l’application de la programmation hors-ligne en projection thermique. En accord avec la démarche de recherche engagée, les travaux de cette thèse se composent de trois parties. Premièrement, les efforts sont dévoués à l’amélioration du module « PathKit » dans le module T.S.T, afin d’optimiser la fonctionnalité de la génération de trajectoires. L’algorithme pour la génération de trajectoires sur un substrat courbe a été étudié de manière à assurer le pas de balayage constant. Une nouvelle trajectoire appelée « Spirale d'Archimède » a été développée pour réparer les défauts formés en projection à froid. La réparation sur une pièce d’aluminium avec un défaut a été réalisé pour valider ce type de trajectoire en spirale d'Archimède. Deuxièmement, des modélisations ont été développées pour simuler l’épaisseur du dépôt en 2D puis en 3D. Puis, ces modèles sont intégrés dans le logiciel RobotStudio™ comme un module individuel dit « ProfileKit ». Dans le « ProfileKit 2D », le module peut évaluer les effets des paramètres opératoires sur le profil du dépôt et puis optimiser les paramètres. Dans le « ProfileKit 3D », l’épaisseur du dépôt peut être simulée selon la trajectoire du robot et la cinématique du robot. Les fonctionnalités sont validées par un dépôt de forme trapézoïdale élaboré par la projection à froid avec des pas de balayage varié. Troisièmement et dernièrement, l’analyse cinématique du robot a été étudiée pour optimiser sa performance pendant le processus de projection. Afin de mieux évaluer la performance du robot, le paramètre « overall parameter » (OP), qui correspond à la moyenne pondérée de l’écart-type de la vitesse articulaire, est introduit pour mesurer la complexité de la trajectoire