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Overcoming the Challenges of Blade Coating in Power Plants | High-Precision Vision-Based Automated Spraying Equipment Put into Practical Use
In the operation and maintenance processes of thermal power equipment, the application of anti‑corrosion coatings to the last‑stage blades of steam turbines is a critical manufacturing step. The conventional manual coating approach relies heavily on operator experience, exhibiting significant shortcomings in managing complex curved‑surface trajectories, ensuring uniform coating thickness, and achieving operational efficiency, while also posing health risks to workers due to the harsh working environment. To address these pain points associated with this non‑standard process, our company has independently developed a solution leveraging the synergistic integration of 3D visual recognition, robotic systems, automated control, and specialized tooling. High-Precision Vision-Based Automatic Spraying System , completing the custom design of the entire equipment set, in‑factory commissioning, and on‑site implementation.
I. Customized Solutions for Special Operating Conditions Automation system
In light of the characteristics of the final-stage blade coating process for steam turbines, KunRobot has customized the overall equipment architecture. The complete automated coating system consists of: Robotics system, 3D vision recognition system, rotor bracket system, industrial PC, control cabinet, quick‑change tooling for sandblasting and spray guns, blade‑coating tooling It consists of multiple modules. Through the coordinated operation of these systems, it enables a complete workflow—from workpiece positioning and tool changing to trajectory planning and automated spraying execution. Meanwhile, the equipment is designed specifically for power plant site conditions and can meet indoor…
Operating under conditions of up to 45°C temperature and relative humidity ≤80%, it is compatible with a 380V three-phase industrial power supply, ensuring stable performance for field applications.
II. 3D Visual Recognition and Positioning Enable Precise Spray Coating Control
For complex curved-surface workpieces, precise positioning is critical to ensuring optimal coating results. The project is equipped with a high-precision 3D vision system that, through visual acquisition and analysis, determines the position of the blades.
Precise identification. Combined with robotic motion control, it achieves: Robot tool coordinate calibration, rotor initial position coordinate calibration, and blade spray start position calibration. The vision system works in tandem with the robot to provide precise data support for executing the spray‑coating trajectory. Meanwhile, the system employs an ABB robot as the execution unit; the robot has a payload of 60 kg, an arm reach of 2,050 mm, and a repeat positioning accuracy of ±0.06 mm, ensuring stable, high‑precision spraying.
III. Multi-System Coordination for Automated Spraying Operations
To reduce the intensity of manual operations, this system has achieved automated, coordinated execution of the coating process. The robotic system can automatically pick up, install, and remove sandblasting guns, spray guns, and vision‑recognition systems, enabling rapid tool changes between different workstations. Meanwhile, an electric roller carriage drives the rotor to perform indexed rotation while maintaining stable operation, preventing any lateral movement in the X and Y directions and providing a reliable foundation for precise robotic spraying. Through the coordinated interaction of the robot, the vision system, and the rotor carriage, the sprayed coating path is fully compliant with process requirements.
IV. Addressing Non-Standard Manufacturing Challenges from a Process‑Driven Perspective
The essence of non-standard automation equipment lies not in merely assembling components, but in designing a system tailored to address real‑world production challenges. From initial on-site surveys and solution planning, through structural design and equipment manufacturing, to final system commissioning, every stage requires continuous refinement based on the specific application context. The development project for a high‑precision vision‑based automatic spraying system represents Bona Intelligent’s practical endeavor in the fields of robotic applications, visual recognition, and intelligent equipment integration.
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