Virtually all coating technologies can be integrated into robotic systems, including:

Atomizers, Electrostatic application (ESTA), Rotary bells, Powder coating

Depending on the application, several programming methods are available:

Point-to-Point Programming: The robot is manually guided from point to point using the control unit, and the individual positions are taught into the system. This method is rarely used in modern coating applications.

Offline Programming: The paint booth, robot and workpiece are modelled in a virtual 3D environment. Intelligent software tools allow engineers to simulate and optimize the coating process directly on a PC. The program is then validated on the real system and fine-tuned where necessary.

Self-Teach Programming: Designed for simpler but highly variable geometries, this method uses predefined coating strategies assigned to the robot. Upon entering the booth, the workpiece is scanned in 3D and automatically analysed. For example, when coating windows, the system identifies interior, exterior and front surfaces independently. The software generates the robot program automatically, allowing the coating process to begin immediately. This solution is particularly suitable for large hanging assemblies and batch size 1 production.

Teach-In Programming: The painter physically guides the robot through the coating process. The robot records the movements and reproduces them precisely, including the painter’s natural application technique. This method is particularly effective for complex geometries and frequently changing workpieces, as often encountered in contract coating operations.

The required expertise depends on the application and the selected programming method.

With modern 3D programming tools, robot programming can be learned by a wide range of users.

Teach-in programming is typically performed by experienced painters who understand coating quality requirements and application techniques.

Self-teach programming is largely automated and requires little to no operator interaction. When integrated with our SmartMES, coating programs and process parameters can be assigned automatically based on the production order and hanging assembly.

Robot programs are typically stored centrally and are ideally called up automatically by the control system, enabling highly automated production processes.

In practice, numerous variables must be considered, including different coating materials, colours, layer thicknesses and application parameters. These requirements can quickly result in a large number of robot programs.

Our SmartMES simplifies this complexity by managing programs, process data and production parameters automatically, ensuring efficient operation, high process reliability and consistent coating quality.