Automatic Wall Painting Robot
Automatic Wall Painting Robot
3, (2020) 1
Abstract— The main aim of this research is to design and optimize equipment operations, safety improvement, quality
develop an automatic wall painting robot for painting multiple improvement, and so on. Painting, in general, has been
colours. In the designed robot, an automatic painting mechanism implemented in industrial factories but not in construction
has been made for painting two different colours by the use of an purposes. Automation will have a great impact on
air compressor and spray guns. Also, a vertical and horizontal construction fields since it uses machines instead of human
systems have been made for the painting mounting of the spray labors to control systems and execute painting operations to
guns. The performance of the developed robot was tested by five improve the quality of the paint job. The painting chemicals
different testing which were DC motor testing, Stepper motor may have the possibility of causing eye and respiratory system
testing, Paint testing, Liquid level sensor testing, and efficiency
problems to painters. The appropriate reason for applying
testing. The designed project has the ability to paint an area of
0.270 m2 in 26.760 minutes which has an accuracy of 96.476%.
automation in the construction of buildings is to increase
The efficiency of the painting system has an efficiency of 96.296% productivity and quality of the paint which varies between
in terms of the painted area. The painting efficiency increased by walls and rooms due to the fatigue of painters. To meet the
decreasing the separation distance between the wall and the robot current demand of the automation process, construction field,
and fixing a pressure to be 4.5 bar. The overall efficiency of the especially in interior buildings, need to be automated to ensure
entire system has been obtained which was 83.987%. The system that the quality is always maintained as a robot is much less
has a strong mobility system for reducing the vibration generated prone to error compared to humans [2].
by the stepper motors. There were three CNC linear lead screw 500
To achieve the automation term in the industry, robots and
mm each fixed on the mobility system of the hardware. Two lead
screws were fixed vertically and one lead screw was fixed into the
automatic systems using sensors should be implemented.
two vertical sliders horizontally. The system uses a rocker switch Nowadays, robots are being used in many applications such as
3-way to either select one of the two colors to be applied into the medical, military, entertainment, etc. However, robots are not
wall or leave the slider to continually move till it reaches a specific being widely used in construction fields since manual
area to select the color to paint that special area. conventional methods are still used. The word robot implies
different meanings to different people since they don’t know
Keywords— Wall Painting Robot; DC motor; Air much about it. A robot is a machine that resembles a human
Compressor; sensors; Efficiency being and it is cable of replicating certain human movements
and functions automatically. Robots can be used in different
I. INTRODUCTION fields but the ones implemented in construction fields are
Wall painting is a repetitive process in which it requires known as construction robots which are smart machines which
the same procedure of painting that makes it boring for use sophisticated, and intelligent languages for their
humans. Since wall painting is a tiring, dangerous process processors and microcontrollers. All in all, robots are
carried out by humans, makes it a perfect case for automation. designed and developed to improve the quality work and
For decades, painting depends on many factors that help reduce the risks in the construction fields since they are very
humans achieve the process such as scaffolds which is used helpful in doing painting operations under dirty and dangerous
instead of ladders as a conventional method for painters to conditions [3].
reach a specific height of a building. Also, manual wall Researches have been conducted in the past regarding
painting requires extra work to achieve the process such as using automation for interior wall painting in the construction
carrying painting materials, lifting painting equipment, industry since exterior wall painting had been implemented in
pushing unnecessary stuff, etc. Moreover, carrying the the construction industry. However, there has been no solid
painting equipment such as spray gun, roller, or a brush for a development due to certain gaps in ideology and technology.
long time may end up in stress and backbone injuries due to The nature of challenge for the automatic wall painting with
the repetitive use of the same part of the body [1]. multiple color will be to identify the dimensions of the wall,
The construction industry is a labor-intensive which is to ensure the painting of the entire wall, to ensure of having
carried out in dangerous situations; therefore, implementing even coatings, thickness uniformity, and avoid any saturation,
robots in construction industries has been realized and it is to ensure of keeping the paint inside the tank within a specific
grown rapidly. The automation has been introduced in the level of height, and to ensure to paint the wall with colors as
early’ 90s to the construction industries. Automation aimed to desired. The system should consist of a simple control system
that can reduce the vibration being produced by the movement
Journal of Applied Technology and Innovation (e -ISSN: 2600-7304) vol. 4, no. 3, (2020) 2
[4]. The research questions have been identified and are listed Therefore, the painting setup is connected to the lead screw
as follows: that moves vertically down based on the rotation of the lead
screw. A gripper is the main part that holds the painting spray
1. Can the system work without any human assistance? for the painting operations in which the gripper causes the
2. Will the system be able to achieve a better result than spray gun to release the paint. The motor is the one responsible
humans? for the gripper to release the spray to paint the wall since it is
already programmed through a microcontroller. The vertical
3. Can the robot move vertically and horizontally without any system proposed by [10] uses a screwed sprayer movement
human assistance? stands for the vertical movement to align with the wall that is
4. Will the robot be able to have an online checking system needed to be painted. Therefore, the vertical system of the
once needed? robot is achieved through a screwed sprayer moving up and
down as a rotation of a screw to allow the spray to paint the
5. Will the robot be able to cover all angles of the wall and wall in the Z-direction. In a study of [11], the robot is very
ensure to paint them? flexible due to its vertical movement mechanism. The robot
6. Can the robot ensure high quality of paint job compared to consists of the screw, nut, and lifter screw that are held in two
humans? ball bearings and nut connected to the frame of the screw. The
entire vertical system is placed on the base frame by using the
Therefore, the main aim for this research is to design and pinion shaft, main shaft, and holder bracket. The functionality
develop an automatic wall painting robot that is fast, precise, of the ball bearing is to hold the main shaft which is welded
reliable, and helps to achieve low-cost painting into the frame. A speed adjuster is used to obtain the required
operations. While the oobjectives is to: (i) design and develop speed of the vertical system due to the ball bearings
a wheel-based robot with a spray gun system with multiple arrangement.
colors to paint the wall. (ii) design and develop a system for
the spray gun to move horizontally and vertically. (iii) design The mobility system and horizontal system for this robot
a system to keep checking of paint level and send an alert. (iv) as per [7] proposed consists of many things that give the robot
evaluate the reliability and efficiency of the system by the ability to do its vertical painting tasks by the arm of the
investigating the consistency of the layers of paint along the robot. The mobility of this system has a movable base that fits
whole surface. the arm to have 3 DOF which are 2 arm joints for moving
linear direction and one for rotational direction to adjust the
[5] aimed to overcome the conventional methods of robot to the wall. Many decisions were discussed about the
painting which uses human labor all the time as well as to number of wheels a robot should have. [12] have said that the
reduce human efforts involved in the whole painting process. mobility system is the main part of the whole system since all-
The vertical system implemented in this research uses a electric and mechanical components are stored inside it. the
mechanism that runs through the chain- sprocket which holds mobility of the robot has many tasks but the important ones
the pneumatic mechanism that allows automatic painting of are to hold the upper portion of the system which is used to
the wall. Sprockets are the main parts that give rotational paint the walls and the other one is a storage house to keep all
movements to the chain. Sprockets are a rotating part that has electrical connection circuits inside it. The robot proposed by
teeth used in conjunction with a chain to transmit torque. [13] is mainly designed in a way that it is capable of achieving
While [6] used a mechanism that works on the principle of a the painting mechanism in an efficient way in which less
scissor lift mechanism for the vertical system A scissor lift power is wasted due to the less number of moving parts used
mechanism depends upon the elongation of collapsible in the robot. The robot is mainly designed by using few sheets
mechanism to provide vertical elevation in Z-direction in ratio of steel welded together to make the base of the robot that
to a rotational or linear input. In this project, a scissor lift is stores the controller unit along with the spray gun, conveyor,
constructed by using supports that can be linked and folded in and the rest of equipment used to build the robot. In a study
a crisscross pattern. The mechanism of the scissor lift can be of [14], a robot designed is considered a good robot since it is
achieved through a different mechanism such as hydraulic not very bulky and it is compact because of having such a high
process, pneumatic process, or mechanical process. On the speed and pressure capabilities for the painting mechanism.
other hand, [7] proposed a scissor lift mechanism for the the robot has two main parts which are the frame stand and
vertical movement of the robot. Along with the scissor lift, wheel building. For the mobile platform of the robot, it
the arm of the robot has an essential motion of 2DOF. The consists of a frame stand, wheels, DC motors, battery, and
vertical motion is into the direction of the wall surface. The control unit. The spray gun mount components are all fixed
vertical motion in addition to the scissor lift is completed by either into the frame stand of the robot or kept inside the base.
the arm mechanism. The arm consists of two joints driven by [15] proposed a painting system for the robot that consists of
stepping motors with fast D.C servo motors. The joint driving a spray gun to paint the specified walls. The spray gun is fixed
mechanisms are being inserted at each joint of the link arm. In into the robotic arm to do the painting process. Therefore, the
addition, [8] implemented a vertical system that depends on robotic arm is mainly implemented for the painting spray gun
cables which are fixed into wheels which are attached to the which is fixed at the tip. The paint is pumped from the bottom
bottom of the frame. This robot aims to design a system for level in the paint tank passed through a solenoidal valve until
exterior wall painting in which it has the capability of painting lastly the spray gun is programmed to spray the paint.
interior walls since it has vertical and horizontal movements
that allow the robot to cover all X-direction, Y-direction, and II. PROPOSED SYSTEM METHODOLOGY
Z-direction. The wheel has a hole from the center to let the end The block diagram for the system designed shows all the
of the connection rods be attached to it as well as to the bottom electrical components used for making the system. Fig. 1.
of the roller handle. In a study done by [9], the vertical system shows the overall block diagram of the system;
implemented in this robot has a mechanism of a lead screw.
Journal of Applied Technology and Innovation (e -ISSN: 2600-7304) vol. 4, no. 3, (2020) 3
Fig. 3. shows the robot with its main control unit opened.
The main control unit works as a cover for the mobility system
that has all the connections made for the system along with the
electrical and electronic components used.
Fig. 2. Overall schematic breadboard diagram of the entire system Fig. 5. 3D bottom-view of the designed robot
Journal of Applied Technology and Innovation (e -ISSN: 2600-7304) vol. 4, no. 3, (2020) 4
Fig. 6. shows a side-view of the designed robot in which The automatic wall painting robot has been designed in a
almost all main devices such as spray guns, lead screws, etc., way that paints one color at a time. The robot has been
designed with using many different parts which were all
integrated to make an entire system that executes the four
objectives of the project. The system can paint two colors once
at a time by selecting the desired color from the rocker switch
3-way. The main control unit of the robot has an ON/OFF
switch, a rocker switch-3-way, 3 LEDs for one spray gun, and
other 3 LEDs for the other spray gun. The mobility system for
the designed robot consists of a square chassis made up of
aluminum profile with vertical aluminum support that holds
the two vertical lead screws. There are three lead screws 500
mm each. Two are fixed vertically into the frame of the robot
while the third one is fixed horizontally into the two sliders of
the vertical lead screws. The spray gun mounting is fixed into
the slider of the horizontal lead screw in which it moves in a
rotated square wave pattern.
III. HARDWARE IMPLEMENTATION
A. GRAPHICAL USER INTERFACE (GUI)
Fig. 6. 3D side-view of the designed robot
Fig. 8. shows the main GUI made for the designed system
The Flowchart of the system will show the entire working in which it has two different options to choose. The first option
principle of the automatic wall painting robot with two colors is to monitor the level of the paint inside the tank which can
in an easy way for better understanding of the system. show the reading under LIQUID LEVEL INDICATOR
option which indicates 0. The second option is to choose the
color wanted for the RGB sensor to detect. This enhancement
was not completely working since the RGB sensor was giving
a source of bad reading and it was not well integrated with the
ultrasonic sensors used in the system. Also, the reading of the
data for the liquid level sensor was not that accurate since the
system is not stable and it produces some vibrations on the
hardware which makes the readings inconsistent and
inaccurate. Those two things could be better enhanced in
future for making a better system that can be controlled
remotely. Also, the RGB sensor could be implemented for a
robot that is designed for making paint designs on the wall.
B. PROTOTYPE
Fig. 9. shows that the designed robot has two painting
Fig. 7. Overall flowchart of the entire system
nozzles for spraying two different colors. There two vertical
lead screws and one horizontal lead screw.
Journal of Applied Technology and Innovation (e -ISSN: 2600-7304) vol. 4, no. 3, (2020) 5
Relative Accuracy % = accurate results. The average time taken for the carriage to
Time with load−Time without load clear 450 mm distance without load was found to be 2.376
100 − | x 100%| (1) minutes while with the load it was 2.418 minutes in which the
Time with load
the average accuracy for the system was 77.642 % in difference time between them was found to be 0.041 seconds.
which the limiting error of the system is within ± 6.222 Meaning that the limiting error for the system is within ±0.041
seconds. seconds.
3) DC Motor Testing
Vertical Stepper Motor For the designed system, there are four DC motors used
Time Reading - With Load Vs. for the movement of the robot on the ground. The motors are
controlled by using an MDDS10 driver which is powered by
Without load 12V power supply. There are two different testing carried out
for the DC motor on 10 different type of grounds. This test
40
will investigate on the voltage of the DC motor when there is
TIME IN SECONDS
12
Without load 11.8
11.6
2.5
1 2 3 4 5 6 7 8 9 10
TIME IN MINUTES
2.4 READINGS
2.3
Voltage when load Voltage when no load
2.2
1 2 3 4 5 6 7 8 9 1011121314151617181920
Fig. 14. DC motor voltage testing graph
READINGS
B. Speed Test
Duration without load Duration with load Speed test is carried out to obtain the actual speed of the
motor when the motor runs on full load which is the load of
the robot which is 20 kg. The no load speed of the motor is 24
Fig. 13. Horizontal stepper motor time reading graph
RPM. The load speed will be obtained by finding the linear
Based on the data collected, the system assumed to be perfect velocity of the robot in which it will be used to obtain the load
since the obtained average accuracy of the system was 98.225 speed.
%. Formula (1) was used to obtain the accuracy. The Test procedure:
horizontal testing was for two square wave patterns to obtain 1. The system was switched on.
Journal of Applied Technology and Innovation (e -ISSN: 2600-7304) vol. 4, no. 3, (2020) 7
2. The testing distance was set to be 500 mm (50 cm) for C. Paint Testing
10 different grounds.
This test carried out to investigate on the painting quality
3. Time to cross was measured. according to the pressure used in the system. There are two
4. Linear velocity was calculated for 10 different grounds spray guns were used in the system to spray two different
by using the following formula; colors. The diameter of the nozzle is 1.5 mm in which it has a
Distance in meter
Velocity (V) = (2) spraying distance of 15 cm to 20 cm. The area of the actual
Time in seconds
5. Speed was calculated for all 10 different grounds by wall that has to be painted is assumed to be 520 mm width and
applying the following formula; 520 mm length which is 0.270 m2. The capacity of the paint
60 tank is 1200 mL which is 1.2 L. The paint level used in the
NRPM = V −1 (3)
2π x r m.s system is 1 L since 0.2 L kept empty for the circuit connection
6. All results were recorded and tabulated. of the sensor.
7. Accuracy was obtained by the following formula;
Test Procedure
RELATIVE ACCURACY % = 100 −
NO LOAD SPEED−LOAD SPEED
1. The system was switched on.
| X 100%| (4) 2. Initialization of home position was reached.
NO LOAD SPEED
3. Desired color was selected.
4. Air compressor was on.
5. A distance of 20 cm was set between the robot and the
DC Motor wall.
Speed Reading - With Load Vs. 6. Spray gun was started painting.
7. Different pressure values were used.
Without load 8. Painted area of the wall was measured.
24 9. A distance of 15 cm was set between the robot and the
SPEED IN RPM
20 wall.
16 10. Step 1 to 8 were repeated.
12 11. All results were recorded and tabulated.
8 Based on the result obtained for the painting operation of
4 the system, the system is capable of performing a good
0 painting operation to reduce the cost of the traditional painting
1 2 3 4 5 6 7 8 9 10 process and the hazards painters face of operating a manual
painting process. Two tests were performed in terms of
READINGS distance in which the separation distance used as 20 cm and
15 cm. The best accuracy obtained was when the pressure 4.5
Calculated Speed Actual Speed bar for a 15 cm distance which was 98.077 %. When the
pressure was set at 5 bar, the painted area exceeded the desired
area by 30 mm for 20cm and 40 mm for 15cm. The rating scale
Fig. 15. DC motor speed testing graph was according to the area painted. The more area painted
within the limited scale, the better the painting quality is. The
The DC motor system is applicable to use for such an average accuracy for the entire system according to all used
application. There were 10 grounds used for obtaining the best pressure was found to be 46.291 %.
accuracy of the system. Smooth floor was the best to obtain an
accuracy of 70.625. The accuracy for the rest of the grounds
were all below 60%. The average accuracy of the motors was
obtained to be 57.419 % in terms of the speed. Painting Operation For 20 cm
Distance
DC Motor Test Pressure Vs. Painted Area
Comparison Reading- Voltage 0.6
Test Vs. Speed Test Vs. Average 0.55
0.5
Accuracy 0.45
AREA IN m2
0.4
READINGS
79.393 0.3
1 57.419 0.25
98.633 0.2
0.13
0.1 0.1
0.05
0 0
Average Accuracy % Speed Test % 1 2 3 3.5 4 4.5 0.55
ACCURACY IN %
Voltage Test % PRESSURE IN BAR
Fig. 16. Overall accuracy of the DC motor Fig. 17. Paint testing graph for 20 cm distance
Journal of Applied Technology and Innovation (e -ISSN: 2600-7304) vol. 4, no. 3, (2020) 8
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