Robot speed & RL turn table calculation
12-13-2015, 12:14 AM,
#1
Robot speed & RL turn table calculation
Hi! To all,
Can you please explain how to calculate the robot speed and turn table feed for plasma & HVOF process? If my component diameter is14" ,it will be a great favor if someone brief
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12-13-2015, 08:37 PM,
#2
RE: Robot speed & RL turn table calculation
(12-13-2015, 12:14 AM)demionkrishan Wrote: Hi! To all,
Can you please explain how to calculate the robot speed and turn table feed for plasma & HVOF process? If my component diameter is14" ,it will be a great favor if someone brief


i am using stallite6 HVOF powder to coat Combustion liners, if some one tells the formula to calculate robot speed and 2 axis turn table feed for rotating the component? additional info: DJ2600 Gun to coat the part, 6 axis fanuc robot , 12" distance between gun and component. due to incorrect speed and feed i am getting lines on the component surface..
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12-14-2015, 11:45 AM, (This post was last modified: 12-14-2015, 11:48 AM by Vadim Verlotski.)
#3
RE: Robot speed & RL turn table calculation
You need to increase speed of part (liner) solid. It is best to rotate > 200 rev / min, even better > 500 rev / min. It does not help if you reduce only the robot speed. In this case, you get thick monolayer and local overheating.

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12-14-2015, 10:04 PM,
#4
RE: Robot speed & RL turn table calculation
(12-14-2015, 11:45 AM)Vadim Verlotski Wrote: You need to increase speed of part (liner) solid. It is best to rotate > 200 rev / min, even better > 500 rev / min. It does not help if you reduce only the robot speed. In this case, you get thick monolayer and local overheating.
Hi! Vadim, and All experts
Thank you for replying my question and encourage me. I would like to introduce myself, I am D.K.Francis from Srilanka basically i am an accountant, i displace to Saudi Arabia to find work and started to work as Thermal Spray Operator and working since 2014. I am not an expert and i don't have much knowledge about Coating. I joined SEF to build my skills and Knowledge. We have standard programs for all components and only need to setup fixture and operates the machine that's it i have done for all these years. Now little by little i have learnt repairing or trouble shooting 9MC, DJC Control Panels, Powder feeders and Hoopers, reparing guns such as 3MBTD, 7MB,9MB,11MB, DJ2600, i-Pro and Plazjet. Changing gears on RL Turn tables and trouble shooting critical alarms in Fanuc robots. currently i step forward to learn robot programming, so far i can create basic teach pendant programs, but i don't know how to find actual feed and speed rates so i need the formula ...our turn table max speed is 300 RPM and i am using M710i C/50 FANUC robot, eg: L p[1] 13mm/sec CNT100 CTV20

how to find 13mm (robot speed) and CTV 20 (300max rpm*20/100) and what is CTV?? Can you please guide me??


god bless you all,
Regards,
Francis
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12-15-2015, 08:49 PM,
#5
RE: Robot speed & RL turn table calculation
To calculate your spray parameters:

1. Calculate rotational speed of the part to achieve a surface velocity of 1 - 1.5 m/s. Velocity = radius * (2 pi()/revolution).
2. Traverse velocity = step * rotational speed where step is mm/revolution and rotational speed is revolution/second.

In your example, your part has a diameter of 14", so your radius is approximately 175 mm. To achieve a surface velocity of 1.5 m/s, you will need to turn the part at 1.4 rev/sec or ~ 84 rpm. Assuming a 6 mm spray spot with your gun, you would set your robot speed to 8.4 mm/s. The robot may require an integer, so set it to 9 or 10. You can make multiple passes over the part to ensure a uniform coating thickness.
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12-15-2015, 10:35 PM, (This post was last modified: 12-15-2015, 10:41 PM by Vadim Verlotski.)
#6
RE: Robot speed & RL turn table calculation
(12-15-2015, 08:49 PM)djewell Wrote: To calculate your spray parameters:

1. Calculate rotational speed of the part to achieve a surface velocity of 1 - 1.5 m/s. Velocity = radius * (2 pi()/revolution).
2. Traverse velocity = step * rotational speed where step is mm/revolution and rotational speed is revolution/second.

In your example, your part has a diameter of 14", so your radius is approximately 175 mm. To achieve a surface velocity of 1.5 m/s, you will need to turn the part at 1.4 rev/sec or ~ 84 rpm. Assuming a 6 mm spray spot with your gun, you would set your robot speed to 8.4 mm/s. The robot may require an integer, so set it to 9 or 10. You can make multiple passes over the part to ensure a uniform coating thickness.

There are in the matter two reasons:

1. Eliminate the spiral in the coating.
2. Reduce thickness of monolayers.

At the first point is important only to choose the correct relation of revolution of the liner and robot speed; the two parameters can be arbitrarily low. In reality, certain speed must not be lower than the definite minimum, because otherwise the monolayers are too thick and the coat flakes off.
84 rpm and 8.4 mm/sec range to eliminate spiral, but may be too little to get thin monolayer. I recommend to use the maximum speed of the table (300 rpm) to be on safe side.
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12-15-2015, 11:56 PM,
#7
RE: Robot speed & RL turn table calculation
Thank you djewell and vadim. your help is really appreciated also it will help others too get knowledge. I feel, the turn table will run with gears and servo motors so if our component weight is above 15kg we can't go with high speed.
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12-16-2015, 11:05 PM,
#8
RE: Robot speed & RL turn table calculation
You can adjust your feed rate to achieve the layer thickness you want. The important point here is to set your rotational and traverse speeds to get good coverage without overheating the part.
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05-11-2020, 08:28 PM,
#9
RE: Robot speed & RL turn table calculation
THANKS Wink
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05-12-2020, 07:32 PM,
#10
RE: Robot speed & RL turn table calculation
This one has been around for quite a while. The way I go about it is to first decide the surface speed desired. Let's use 70 M/Min. You must know the diameter of the part in order to figure the circumference. Dia. = 14" in the original question. We cannot mix apples and oranges so convert to metric: 14 x 25.4 = 355.6 mm. Formula for circumference, pi(simplified), 3.14 x 355.6 = 1185.6 mm circumference. Now we are ready.

70 M =70,000 mm/1185.6 = 59 RPM

You want 60 M/Min or 120 M/Min? Fine, substitute that number in the formula. Let's move on then. (RPM x Step distance)/60 Seconds. In this example it is (59 x 5)/60 = 4.9 mm/sec. I chose 5 mm step, you put in 5 or whatever you need. No substituting another number for 60 because it is constant that there are 60 seconds in a minute. Big Grin

One other thing I worked out is to back check your step distance. (60 x traverse rate)/RPM gives you your step distance. Yes 60 is for seconds, no substitutions. Why is this useful? Say for instance you have a small diameter part for which you cannot possibly rotate fast enough so you set table to max speed, maybe 300 RPM. In order to tune in the step distance you want, plug in different traverse rates to get the step that you desire.
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