Chapter 1
Chapter 1
CHAPTER 1
INTRODUCTION
1.1 General
Building and construction is one of the important industries around the world. In this fast
moving life construction industry is also developing expeditiously. But the labours in the
construction industry are not sufficient. This inadequate labours in the construction industry is
due to the complexity in the work. In construction industry, during the work in giant buildings
or in the sites where there is more dangerous situation like interior area in the city. There are
some other reasons for the unsatisfactory labours which may be because of the improvement
the education level which cause the people to think that these types of work is not as esteemed
as the other jobs.
The construction industry is labour-intensive and conducted in risky situations; therefore, the
importance of construction robotics has been realized and developed at speed. Applications
and activities of robotics and automation in the construction industry started in the early 90’s
aiming to upgrade equipment operations, improve safety, modify concept of workspace and
furthermore, ensure quality environment for building occupier. After the advances in the
robotics and automation the construction industry has developed very fast. In contempt of the
advances in the robotics and its wide spreading applications, painting is also considered to be
the tough process & it also has to paint the whole building. To make this work easier, secure
and also to reduce the number of labours the remote operated spray painting machine was
introduced. Above all these the interior wall painting has shared slight in research activities.
The painting chemicals can cause hazards to the human painters such as eye and respiratory
system. Also the nature of painting procedure that requires recast the work and hand rising
makes it tedious, time and effort consuming. These factors inspire the development of remote
operated spray painting machine. This project aims to develop the interior wall painting robot
which is remote operated. This Three Axis Spray Painting Machine is not designed by using
problematic components. This robot is simple and movable.
The robot is designed by using few steels, steel rods, spray gun, electric motor and a controller
unit to handle the entire operation of the robot. This robot is compact due to moderate speed
and pressure capabilities they have. They also have a small weight to power output ratio and
expected performance i.e. losses are minimum due to less number of moving parts are use in
this machine and so gives expected performance. Due to elegant and simple control systems it
can control noise, vibration and does silent & decent operation and small amount of vibration
is produced. It has longer life, flexibility, efficient and trustworthy. The installation and
maintenance is easy. Some of the conditions that have to be examined while using this robot is
that the system is operates, so it needs airless spray gun and plastic barrel etc.
Early paint robots were hydraulic versions, which are still in use today but are of inferior
quality and safety to the latest electronic offerings. The newest robots are accurate and deliver
results with uniform film builds and exact thicknesses. Originally, industrial paint robots were
large and expensive, but robot prices have come down to the point that general industry can
now afford the same level of automation used by the large automotive manufacturers.
The selection of modern paint robot varies much more in size and payload to allow many
configurations for painting items of all sizes. Painting robots generally have five or six axis
motion, three for the base motions and up to three for applicator orientation. These robots can
be used in any explosion hazard Class 1 Division 1 environment.
Industrial paint robots are designed to help standardize the distance and path the automatic
sprayer takes, thus eliminating the risk of human error caused by manual spraying. Paint robots
are often paired with other automatic painting equipment to maximize the efficiency and
consistency of the paint finish. Rotational Bell atomizers, other automatic electrostatic or
automatic conventional sprayers are mounted on the robot to provide the highest quality finish.
Automatic mixing equipment will usually supply the sprayers with paint. This equipment is
designed to regulate pressure and flow, which are extremely important in providing consistent
paint finish. Varying levels of automatic mixing equipment can also provide features that cut
down on paint waste, and energy costs.
Robotics is the interdisciplinary study and practice of the design, construction, operation, and
use of robots. Within mechanical engineering, robotics is the design and construction of the
physical structures of robots, while in computer science, robotics focuses on robotic
automation algorithms. Other disciplines contributing to
roboticsinclude electrical, control, software, information, electronic, telecommunication, com
puter, mechatronic, and materials engineering.
The goal of most robotics is to design machines that can help and assist humans. Many robots
are built to do jobs that are hazardous to people, such as finding survivors in unstable ruins,
and exploring space, mines and shipwrecks. Others replace people in jobs that are boring,
repetitive, or unpleasant, such as cleaning, monitoring, transporting, and assembling. Today,
robotics is a rapidly growing field, as technological advances continue; researching, designing,
and building new robots serve various practical purposes.
Robotics usually combines three aspects of design work to create robot systems:
Mechanical construction: a frame, form or shape designed to achieve a particular task. For
example, a robot designed to travel across heavy dirt or mud might use caterpillar tracks.
Origami inspired robots can sense and analyse in extreme environments. The mechanical aspect
of the robot is mostly the creator's solution to completing the assigned task and dealing with
the physics of the environment around it. Form follows function.
Electrical components that power and control the machinery. For example, the robot
with caterpillar tracks would need some kind of power to move the tracker treads. That power
comes in the form of electricity, which will have to travel through a wire and originate from a
battery, a basic electrical circuit. Even petrol-powered machines that get their power mainly
from petrol still require an electric current to start the combustion process which is why most
petrol-powered machines like cars, have batteries. The electrical aspect of robots is used for
movement (through motors), sensing (where electrical signals are used to measure things like
heat, sound, position, and energy status), and operation (robots need some level of electrical
energy supplied to their motors and sensors in order to activate and perform basic operations)
Software.
A program is how a robot decides when or how to do something. In the caterpillar track
example, a robot that needs to move across a muddy road may have the correct mechanical
construction and receive the correct amount of power from its battery, but would not be able to
go anywhere without a program telling it to move. Programs are the core essence of a robot, it
could have excellent mechanical and electrical construction, but if its program is poorly
structured, its performance will be very poor (or it may not perform at all). There are three
different types of robotic programs: remote control, artificial intelligence, and hybrid. A robot
with programming has a pre-existing set of commands that it will only perform if and when it
receives a signal from a control source, typically a human being with remote control. It is
perhaps more appropriate to view devices controlled primarily by human commands as falling
in the discipline of automation rather than robotics. Robots that use artificial
intelligence interact with their environment on their own without a control source, and can
determine reactions to objects and problems they encounter using their pre-existing
programming. A hybrid is a form of programming that incorporates both AI and RC functions
in them.
The Internet of things (IOT) is a system of interrelated computing devices, mechanical and
digital machines that are provided with unique identifiers (UIDs) and the ability to transfer data
over a network without requiring human-to-human or human-to-computer interaction. The
definition of the Internet of things has evolved due to the convergence of multiple technologies,
real-time analytics, machine learning, commodity sensors, and embedded systems. Traditional
fields of embedded systems, wireless sensor networks. control systems, automation (including
home and building automation), and others all contribute to enabling the Internet of things. In
the consumer market, IOT technology is most synonymous with products pertaining to the
concept of the “smart home”, covering devices and appliances (such as lighting fixtures,
thermostats, home security systems and cameras, and other home appliances) that support one
or more common ecosystems, and can be controlled via devices associated with that ecosystem,
such as smartphones and smart speakers. There are a number of serious concerns about dangers
in the growth of IOT, especially in the areas of privacy and security, and consequently industry
and governmental moves to begin to address these.
Kevin Ashton firstly proposed the concept of IoT in 1999, and he referred the IOT as uniquely
identifiable connected objects with radio-frequency identification (RFID) technology.
However, the exact definition of IOT is still in the forming process that is subject to the
perspectives taken. IOT was generally defined as “dynamic global network infrastructure with
self-configuring capabilities based on and communication protocols”.
Physical and virtual things in an IOT have their own identities and attributes and are capable
of using intelligent interfaces and being integrated as an information network. In easy terms
IOT can be treated as a set of connected devices that are uniquely identifiable.
The words “Internet” and “Things” mean an inter-connected world-wide network based on
sensors, communication, networking, and information processing technologies, which might
be the new version of information and communications technology (ICT). To date, a number
of technologies are involved in IOT, such as wireless sensor networks (WSNs), barcodes,
intelligent sensing, RFID, NFCs, low energy wireless communications, cloud computing and
so on.
The IOT describes the next generation of Internet, where the physical things could be accessed
and identified through the Internet. Depending on various technologies for the implementation,
the definition of the IOT varies. However, the fundamental of IOT implies that objects in an
IOT can be identified uniquely in the virtual representations. Within an IOT, all things are able
to exchange data and if needed, process data according to predefined schemes.
Just data collection is not enough in IOT, extraction of knowledge from the generated data is
very important. For example, sensors generate data, but that data will only be useful if it is
interpreted properly. So intelligence is one of the key characteristics in IOT. Because data
interpretation is the major part in any IOT application because without data processing we can’t
make any insights from data. Hence, big data is also one of the most enabling technologies in
IOT field. IOT is able to interact without human intervention. Some preliminary IOT
applications have been already developed in healthcare, transportation, and automotive
industries.
A critical requirement of an IOT is that the things in the network must be connected to each
other. IOT system architecture must guarantee the operations of IOT, which connects the
physical and the virtual worlds. Design of IOT architecture involves many factors such as
networking, communication, processes etc. In designing the architecture of IOT, the
extensibility, scalability, and operability among devices should be taken into consideration.
Due to the fact that things may move and need to interact with others in real-time mode, IOT
architecture should be adaptive to make devices interact with other dynamically and support
communication amongst them. In addition, IOT should possess the decentralized and
heterogeneous nature.
Service oriented architecture A critical requirement of an IOT is that the things in the network
must be inter-connected. IOT system architecture must guarantee the operations of IOT, which
bridges the gap between the physical and the virtual worlds. Design of IOT architecture
involves many factors such as networking, communication, business models and processes,
and security. In designing the architecture of IOT, the extensibility, scalability, and
interoperability among heterogeneous devices and their models should be taken into
consideration. Due to the fact that things may move physically and need to interact with each
other in real-time mode, IOT architecture should be adaptive to make devices interact with
other things dynamically and support unambiguous communication of events.
The network layer of an IOT architecture is responsible for providing communication and
connectivity between devices in the IOT system. It includes protocols and technologies that
enable devices to connect and communicate with each other and with the wider internet.
Examples of network technologies that are commonly used in IOT include
The data processing layer of IOT architecture refers to the software and hardware components
that are responsible for collecting, analysing, and interpreting data from IOT devices. This layer
is responsible for receiving raw data from the devices, processing it, and making it available
for further analysis or action. The data processing layer includes a variety of technologies and
tools, such as data management systems, analytics platforms, and machine learning.
IOT architecture comprises of several IOT system building blocks connected to ensure that
sensor-generated device data is collected, stored, and processed in the big data warehouse
and that devices’ actuators perform commands sent via a user application. The following
diagram reflects our approach to IOT architecture.
CHAPTER 2
V Navina [Link]. (2013), An automated wall painting robot, the primary aim of the project is to
design, develop and implement Automatic Wall Painting Robot which helps to achieve lowcost
painting equipment. Despite the advances in robotics and its wide spreading applications,
interior wall painting has shared little in research activities. The painting chemicals can cause
hazards to the human painters such as eye and respiratory system problems. Also, the nature of
painting procedure that requires repeated work and hand rising makes it boring, time and effort
consuming. When construction workers and robots are properly integrated in building tasks,
the whole construction process can be better managed and savings in human labour and timing
are obtained as a consequence. In addition, it would offer the opportunity to reduce or eliminate
human exposure to difficult and hazardous environments, which would solve most of the
problems connected with safety when many activities occur at the same time. These factors
motivate the development of an automated robotic painting system. [1]
Rutuja Pawar [Link]. (2018), The paper consists of an Automatic wall painting robot, wall
painting is an ideal candidate for automation since it is so repetitive, labour-intensive, and
potentially hazardous. Painting had already been automated in the car industry, but not in the
building industry. It is urgently necessary to paint the interior walls of residential buildings
using a mobile robot that can move. In order to provide lateral feed motion to cover the painting
surface, the arm of the autonomous wall painting robot described in this study is installed on a
mobile robot base and scans the walls vertically. The design aims to satisfy the requirements
of simplicity, lightness, affordability, and speedy painting. Ultrasonic sensors are put on the
arm and the movable base to allow movement while adjusting the mobility constraints. To
organise the movement of the mobile base and govern the arm movement, a control system is
developed. [2]
Rajesh Kannan Megalingam [Link]. (2020), Project titled an Autonomous wall painting robot
is about, Interior wall painting is a common work in construction which consumes a lot of time
and human effort. By replacing human manual operation, robotic painting was introduced to
improve the accuracy, efficiency and to reduce the cost. In this paper, we introduce an
autonomous wall painting robot which can paint the interior walls of a room, using paint
sprayer with the help of a cascade lift mechanism. This cascade lift mechanism assists the paint
sprayer to reach the required heights. The magnum wheels with dc motors that are attached to
the base of the robot, helps in easy movement of the robot, to move in all six directions with 2
DOF (degrees of freedom). The robot uses ultrasonic sensors to detect the distance and adjust
to the walls, and to check whether the sprayer reached the top of the wall. The master controller
controls the ultrasonic sensors, magnum wheels, and all other parts of the robot. The overall
system runs on AC power supply. [3]
Syed Mohd Bahrin [Link]. (2020), Automatic wall painting robot with multiple colours, the
main aim of this research is to design and develop an automatic wall painting robot for painting
multiple colours. In the designed robot, an automatic painting mechanism has been made for
painting two different colours by the use of an air compressor and spray guns. Also, a vertical
and horizontal systems have been made for the painting mounting of the spray guns. The
performance of the developed robot was tested by five different testing which were DC motor
testing, Stepper motor testing, Paint testing, Liquid level sensor testing, and efficiency 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%. The efficiency of the painting system has an efficiency of 96.296%
in terms of the painted area. The painting efficiency increased by decreasing the separation
distance between the wall and the robot and fixing a pressure to be 4.5 bar. The overall
efficiency of the entire system has been obtained which was 83.987%. The system has a strong
mobility system for reducing the vibration generated by the stepper motors. There were three
CNC linear lead screw 500 mm each fixed on the mobility system of the hardware. Two lead
screws were fixed vertically and one lead screw was fixed into the two vertical sliders
horizontally. The system uses a rocker switch 3-way to either select one of the two colours to
be applied into the wall or leave the slider to continually move till it reaches a specific area to
select the colour to paint that special area. [4]
Amgad Muneer [Link]. (2014), Design and implementation of automatic painting mobile robot,
wall painting is a repetitive, stressful, and hazardous process that makes it an ideal automation
case. In the automotive industry, painting had been automated but not yet for the construction
industry. However, there is a strong need for a mobile robot that can move to paint residential
interior walls. In this study, we aim to design and implement an automatic painting mobile
robot. The conceptual design of the proposed wall painting robot consisting paint mechanism
with a spray gun and ultrasonic sensor. The spray gun is attached to a pulley mechanism that
has linear motion. The ultrasonic sensor is used to detect the spray gun when it reached a certain
limit. The DC motor rotates clockwise and counter clockwise based on the ultrasonic sensor
condition made. The experimental results indicate that the robot was able to paint the walls
smoothly vertically, and horizontally. The spraying gun structure's speed is at a tolerable speed
of 0.07 m/s, which could be increased, but to provide high-quality painting without any gaps,
the current speed was selected as the most suitable, without any harm to the working process.
[5]
Sandip Mehta [Link]. (2017), AG Wall P—Automatic guided wall painting system, this paper
presents the development of prototype of Automatic Wall Painting Machine guided by wall
dimensions and paint colour being sent from user through a camera embedded Raspberry Pi 2
module. The Raspberry Pi Module captures the wall image and calculates the dimensions using
Image Processing tools and remotely forwards the dimensions to the base painter system using
Bluetooth transmission. The Mechanical structure consists of a 2-D plotter with the painting
joint attached to a DC operated DCV (Directional Control Valve) spray paint that moves from
a point to another line by line. The plotter runs with two Nema 17 stepper motors and contains
a STM32 as the slave controller, receiving the dimensions via Bluetooth module connected to
it. The overall system is run by a dual shaft Nema 23 Stepper motor. [6]
A Arockia Selvakumar [Link]. (2016), The paper about Development of exterior wall painting
robot, Objective: Exterior wall painting is one of the major tasks in construction field. For
apartment building exterior wall painting is risky. Painter will be hanging on the wall with
support of rope. While painting the painter has to slide down carefully, even sometimes need
to move left and right along the wall. There is a chance of falling if not alert. Method: In this
paper, research is carried out for development of exterior wall painting robot (PAINTBOTEW).
Hardware is divided into two sectors, robot and suspension system. Robot is fabricated by
attaching paint feed roller to the frame. DC motor drives the roller vertically up and down on
the frame using rotating disc and connecting rod. Robot is connected to the cables at top right
and left corners. The other ends of cables are connected to DC geared motors through the
pulleys mounted on the wall at required distance. UI part includes creating Graphical User
Interface (GUI) in MATLAB, coding the program and to control the movement of the robot
using Arduino Uno. Alignment of robot while moving from one co-ordinate to other may vary
but once it reaches the required co-ordinate it aligns itself straight. Motors which were fixed to
the robot for movement; in earlier, robot was attached to the ground in order to reduce
vibrations generated in robot. As well as continuous paint flow is maintained while painting
using pump which is not possible in case of compressor used in earlier robot. Applications:
Wall painting is carried out with 65% reduction in cost along with reduction in vibrations
generated in the earlier model. [7]
Sakshi Chonkar [Link]. (2024), Robotic Wall Painter: An Automated Wall Painting Approach,
the paper about Painting jobs, which encompass a wide range of industries from construction
to automotive manufacturing, rely on skilled workers who possess both artistic flair and
technical expertise. However, painting jobs also come with their own set of challenges and
demands. Workers are often exposed to potentially harmful chemicals and fumes, leading to
health risks such as respiratory problems, skin issues, and long-term exposure-related illnesses.
Worker safety is a paramount concern, and addressing these risks often requires stringent safety
protocols and personal protective equipment, which can add to operational costs. On the
positive side, companies are increasingly adopting automated painting solutions. Automation
improves efficiency, consistency, and safety while reducing waste. Automating painting jobs
brings numerous advantages across industries. Our Project also aims to automate the task of
wall painting using a hardware base using Arduino and stepper motor with an extendable arm
attached to it. The bot will have obstacle avoidance and detection and path projection to
accurately paint the wall. It will feature a UI webpage to help the user interact with the bot. [8]
Ponnandithaa Pillai [Link]. (2024), The project titled Robot paint-the proposed wall painting
robot: A unified control system integrating hardware and software for efficient operation, it is
vital to note that the demand for painters in the construction industry is currently high and
expected to continue increasing in developed and developing countries shortly. However,
relying on manual labour for construction tasks is costly, time-consuming, and less precise and
hazardous to workers' health. The solution to these challenges lies in embracing automation,
leveraging advanced technologies like computer vision and path projection to guide robotic
systems in completing tasks with greater efficiency and accuracy. By adopting this approach,
we can not only enhance productivity but also ensure the safety and wellbeing of workers in
the construction sector. The Algorithm presented in this context is exceptional and offers
several advantages over existing literature. The detailed dynamic model parameters further
enhance the robot's features, making it a significant breakthrough in the construction industry.
[9]
A Sumalatha [Link]. (2024), The paper design and innovations in robotic technology: A smart
robotic design for effortless wall painting using artificial intelligence is A fully autonomous
wall-painting robot is the focus of this paper’s development, expansion, and implementation
efforts. Research efforts have not communicated much about interior wall painting. Numerous
studies have shown that the chemicals used in painting are detrimental to human health,
particularly the respiratory and visual systems. In addition, the monotony, time commitment,
and physical exertion inherent in the painting process are hard to resist. With the right
combination of human and robotic labour, the entire construction process may be optimized,
leading to time and labour savings. Furthermore, it would provide an opportunity to lessen or
eliminate human exposure to challenging and dangerous conditions, which would address most
of the issues, provide protection, and make it happen more often. The study introduces a new
wall painting robot dubbed Smart AI based Wall Painting Robot (SAIWPR). To test how well
the suggested scheme works, it is cross-validated with the traditional Autonomous Wall
Painting Robot (AWPR). The creation of an unsupervised robotic painting system is driven by
the wall painting robot. The design goal is to meet the requirements of being simple,
lightweight, inexpensive, and having a short painting time. To control the range of motion,
navigate the room, ultrasonic sensors are attached to the arm and the mobile base. The arm’s
movement and the mobile base’s trajectory are both managed by a specialized control system.
[10]
D Mamatha [Link]. (2020), Development of Autonomous Wall Painting Robot using Raspberry
Pi and Image Processing: Painting Robot prototype which helps to achieve low-cost painting
equipment. It would offer the opportunity to reduce or eliminate human exposure to difficult
and hazardous environments, which would solve most of the problems connected with safety
when many activities occur at the same time. The system performs the painting process by the
use of image captured by the pi camera. The painting area is calculated and information is
transferred to the spray gun. The painting is done using bound box. Raspberry pi module will
control the base DC motors and the actuator. The actuator while extending and retracting raises
the scissor lift and lowers it, respectively. The spray gun handle is mounted at top of the lift,
while the air compressor is set on the lower platform, and is turned ON/OFF at the bidding of
the raspberry pi module. [11]
Pragathi Reddy [Link]. (2025), The project entitled Automatic Solar Wall Painting Robot is
about Painting walls is a challenging and labour-intensive task that requires ongoing
maintenance to maintain its aesthetic appeal. It requires significant time and manpower to
complete. Painters often face difficulties moving around and reaching high spots, which makes
the process time consuming. The system is powered by a solar panel that charges a battery,
ensuring a continuous renewable energy supply. An Arduino Nano microcontroller, interfaced
with CNC and other modules, controls the various components. Ultrasonic sensors detect
obstacles in the horizontal, vertical, and front directions, stopping the robot's operation to
ensure precision and safety. DC motors manage the robot's movement for wheels and stepper
motors for vertical spray mount adjustments, while a servo motor operates the spray gun. A
pneumatic diaphragm pump delivers paint from a container to the nozzle, and a potentiometer
adjusts horizontal movement. The system also features a Bluetooth module for remote control.
By automating the painting process, especially for high and risky exterior walls, the robot
increases efficiency, reduces manpower needs. [12]
Shaik Mazhar Hussain [Link]. (2023), The paper design of an Automated wall painting robot
for mixing colours based on mobile application, in which the final stage, which is the building
paint or the adopted design, is where most real estate developers and constructors struggle.
Where extensive painting is required, which takes a lot of time, effort, and accuracy from the
firm doing the work. Additionally, it might be challenging to decide on the precise colour
grades for the design and calculate the right amount of paint to use for the job. Where these
activities are extremely expensive, and the complex implementation is accompanied by worries
and scepticisms. These are the motivations behind the development of painting machines that
blend colours. Artificial intelligence is used in the machine's design to make it efficient and
quick at what it does. High accuracy is needed when selecting the proper colours, and this
machine is distinguished by its ability to select the proper colour tone. The colour sensor
(TCS34725 RGB) determines the relevance and accuracy of the desired colour by comparison
with the system database with the assistance of the light sensor (STM32), which measures the
degree of illumination of the chosen place. By combining basic colours, this technique saves
the customer the hassle of looking at specialized stores for the level of colour they require. By
giving the system, the codes assigned to each colour, it may also blend colours. The system
also has the feature of controlling the machine remotely via smart phone application by
enabling Bluetooth and Wi-Fi features. [14]
Utkarsha S Bawane [Link]. (2018), An Automatic wall painting machine [J], the use of spraying
robotized systems for interior painting was already shown to be feasible and convenient, a lot
of experiments must be carried out in the future to deliver a highly autonomous robot for
interior painting. We developed an exterior wall painting robot for the purpose of automating
this painting operation. The robot is mounted on equipment which permits it to move up and
down, left and right along the exterior walls of a building. It is computer controlled and is
activated simply by the operator pressing a switch on the control panel located on the ground.
Automatic Wall Painting Robot which helps to achieve less human interaction and low-cost
painting equipment. Despite the advances in robotics and its wide spreading applications,
interior wall painting has shared little in research activities. Despite the fact that the utilization
of spreading robotized frameworks for inside painting was at that point indicated to be
attainable and helpful, a ton of tests must be completed later on to convey an exceedingly
selfgoverning robot for inner part painting. [15]
Pallavi Giri [Link]. (2024), NextGen Robot: An Efficient and Effortless Wall Painting Robot
Design Based on Artificial Intelligence (AI) Principles, this project is about a fully autonomous
wall-painting robot is the focus of this paper's development, expansion, and implementation
efforts. Research efforts have not communicated much about interior wall painting. Painters’
eyes and respiratory systems are particularly vulnerable to the toxic chemicals used in the
industry. Additionally, the monotony, time commitment, and physical exertion inherent in the
painting process are hard to resist. The entire construction process may be enhanced and time
and labour saved by using robots and human workers appropriately into building jobs. The
Dynamic Smart Painting Robo Model (DSPRM) is a novel robot that this study introduces for
intense wall painting. To test its efficacy, it is cross validated with the usual technique, the
usual Painting Bot (CPB). Furthermore, it would provide an opportunity to lessen or eliminate
human exposure to challenging and dangerous conditions, which would address most of the
issues, provide protection, and make it happen more often. An autonomous robotic painting
system is being developed as a result of the wall painting robot. [17]
2.2 Objectives
o To minimize human efforts, the machine is operated by remote control and to reduce
time requirement for painting, spray gun is used.
CHAPTER 3
3.1 Methodology
Design Consideration
Design Specification
Design Calculations
Design Modelling
Bill of Material
Fabrication
Assembly
CHAPTER 4
An MS frame, or Mild Steel frame, is a strong, versatile construction element made from low-
carbon steel, commonly used for building structures (columns, beams), door/window frames,
and industrial applications due to its strength, ductility, and cost-effectiveness, available in
various finishes like powder coating for enhanced durability and aesthetics.
The Frame Body is made up of M.S. along with some additional light weight components. The
frame is designed to sustain the weight of the component unit, the weight of load to be conveyed
and also to hold the accessories like motor. Also it should be design to bear and overcome the
stresses which may arise able to due to torques and impact loading across the obstacles.
PARAMETER SPECIFICATION
Type DC Motor
Voltage 24 V
RPM 4000
Torque 22 Nm
12 V DRIVE MOTOR
The blade motor used is a 12-volt electric motor. The blade motor is a permanent magnet motor
that operates on the 12-volt battery, which gives the motor enough power to turn the steel blade
at high speeds. The design of the blade motor will remain consistent to that of other electric
mowers except that the microcontroller with a relay on board will control it.
Many applications call for a high start-up torque. The D.C. motor, by its very nature, has a high
torque vs. falling speed characteristic and this enables it to deal with high starting torques and
to absorb sudden rises in load easily. The speed of the motor adjusts to the load. Furthermore,
the D.C. motor is an ideal way of achieving the miniaturisation designers are constantly seeking
because the efficiency it gives is high compared with other designs.
PARAMETER SPECIFICATION
Type Direct chain drive using clutch
Pinion 9 Teeth’s
Module 2.75mm
Pitch 9.2356
Gear Ratio 1.4
Centre Distance 200mm
4.1.4 Sprocket
A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even sprockets that mesh
with a chain, track or other perforated or indented material. The name 'sprocket' applies
generally to any wheel upon which are radial projections that engage a chain passing over it. It
is distinguished from a gear in that sprockets are never meshed together directly, and differs
from a pulley in that sprockets have teeth and pulleys are smooth.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other machinery either
to transmit rotary motion between two shafts where gears are unsuitable or to impart linear
motion to a track, tape etc. Perhaps the commonest form of sprocket is found in the bicycle, in
which the pedal shaft carries a large sprocket-wheel which drives a chain which in turn drives
a small sprocket on the axle of the rear wheel. Early automobiles were also largely driven by
sprocket and chain mechanism, a practice largely copied from bicycles.
The L298N Motor Driver Module is a great choice for controlling motors! It contains a
double H bridge L298N chip, which has a maximum voltage of 46V and a current of 2A.
This L298N High-voltage Dual-channel motor driver works with a logic voltage of 5V and
can drive motors with a voltage range of 5-35V, giving you good efficiency with a
maximum power output of 25W.
One cool feature of the L298N-based motor driver module is that it has current sensing for
each motor, so you can easily check how they’re doing. It also features a heatsink to keep
it cool while running, which increases efficiency. Also, there is a power-on LED indicator
that indicates when it is active. The L298N Module is perfect for controlling DC and
Stepper motors, switches, relays, robotic cars, arms, etc.
Power: Wide input voltage (6-24V via VIN), USB-C port, 5V operation.
Connectivity: USB-C, CAN Bus (requires transceiver), extra I2C via Quick connector.
4.1.7 Bearings
A bearing is a machine element, which supports another machine element. It permits a relative
motion between the contact surfaces, while carrying the load. In this automobile gearbox roller
bearings are adopted. The ball or roller bearing consists of an inner race, which is mounted on
the shaft or journal, and the outer race, which is carried by the housing or casing.
In between the inner and outer race there are balls or rollers. A No. of balls or rollers is used
and these are helped at proper distance by retainers so that they do not touch each other. The
retainers are this strip and usually in two parts, which are assembled after the ball bearings are
used for light loads and roller bearings, are used for heavier loads.
4.1.8 Shaft
A shaft is a rotating element, which is used to transmit power from one place to another. The
power is delivered to the shaft by some tangential force and the resultant torque or tensional
moment set up within the shaft permits the power to be transferred to various machines linked
up to the shaft, in order to transfer the power from one shaft to another the various members
such as pulleys, gears etc., are installed on it. This member causes the shaft to bending. In other
words, we may say that a shaft is used for the transmission of torque and bending. The various
members are mounted on the shaft by means of keys or splines.
Materials Used
The material used for ordinary shafts is mild steel where high strength is required. An alloy
steel such as nickel, nickel chromium or chrome vanadium steel is used.
Manufacturing Technique
Shafts are generally formed by hot rolling and finished to size by cold awing or turning.
There are two types of shafts:
a. Transmission shaft
b. Machine shaft.
Standard Size of Shaft
25 mm to 60 mm with 5 mm step
60 mm to 110 mm with 10 mm step
110 mm to 140 mm with 15 mm step
140 mm to 500 mm with 20 mm step
Standard Length of the Shaft
5 meters
6 meters
7 meters
Stress in Shaft
Shear stress due to transmission of torque. Combined torsion and bending. Bending
stress due to the force acting up on the machine element like gears, pulleys etc. As well as due
to the weight of the shaft itself.
Design of Shaft
The shaft may be designed on the basis of strength & rigidity
Shaft subjected to twisting moment or torque only
Where the shaft is subjected to poor twisting moment then diameter of Shaft.
T/J = τ/R
T = Twisting moment or torque acting upon the shaft.
J = Polar moment of inertia of cross sectional area about the access
Of rotation in mm4
τ = Torsion shear stress NI mm2 or KNI mm2
R = Distance from neutral axis to the outer most layer mm or M
Spray nozzles can have one or more outlets; a multiple outlet nozzle is known as a compound
nozzle. Multiple outlets on nozzles are present on spray balls, which have been used in the
brewing industry for many years for cleaning casks and kegs. Spray nozzles range from those
for heavy duty industrial uses to light duty spray cans or spray bottles.
Shaped-orifice
The shaped orifice uses a semi spherical shaped inlet and a V notched outlet to cause the flow
to spread out on the axis of the V notch. A flat fan spray results which is useful for many spray
applications, such as spray painting.
Figure [Link]: Flat fan spray pattern Figure [Link]: Spray Nozzle
spray nozzle
Discharging (Using Power): Chemical reactions convert lead and lead dioxide into
lead sulphate on both plates, releasing electrons (electricity).
Charging (Reversing): An external power source forces the reaction backward,
turning lead sulphate back into lead and lead dioxide, storing energy.
Specifications
Filled Weight 2 KG
Model Name/Number SDL-12-8
Battery Charging Time 20 Hours Working Capacity
Usage/Application Agriculture Sprayer Spare Parts
Weight 2.1 Kg
Packaging Type Box
Voltage 12 V
Battery Capacity 8 Ah
Charging Temperature 25 Degree C
Voltage Regulation 1.8 V
Initial Current 2.4 A
Battery Type Sealed Lead Acid Battery
Specifications
Thread Size M4
Material Stainless Steel
Length 1m
Thread Length Style Fully Threaded
Stainless Steel Type A4 316
Standards Met DIN 976
Finish Plain
4.2.2 Chain
DIN/ISO NO : 520
CHAPTER 5
5.1 Control Configuration
Arduino Controller
Prototype Board
Motor Drive
Pump
Lead Acid Battery
Switch ON/OFF
Plant/Crop
DC MotorField
Spray Tank
Nozzle
System Initialization
The operation of the wall painting robot begins with switching ON the power supply using a
12 V/24 V DC battery system. Once powered, the controller initializes all connected motors
and sensors. The robot is then positioned near the wall to be painted. Remote control is used to
guide the robot, ensuring safe operation without direct human contact with paint chemicals or
hazardous working conditions.
The horizontal movement of the robot along the wall surface is achieved using a DC drive
motor coupled with a chain and sprocket mechanism. This motor is mounted on the base frame
of the robot and is connected to the wheels through a chain drive system.
The vertical movement of the spray gun is achieved using a lead screw and nut mechanism
driven by a DC motor mounted on the top frame of the robot.
When the vertical motor rotates, the lead screw converts rotary motion into linear motion. The
nut attached to the spray gun assembly moves upward or downward along the threaded rod.
This motion enables the spray gun to scan the wall vertically from bottom to top or vice versa.
By synchronizing vertical movement with horizontal motion, the robot ensures complete wall
coverage without missing or overlapping areas.
The Z-axis controls the distance between the spray nozzle and the wall surface, which is crucial
for uniform paint application and reduced paint wastage. The spray gun is mounted on an
adjustable frame that allows forward and backward movement. This prevents excessive paint
accumulation, dripping, or uneven coating on the wall.
An electric spray gun that atomizes the paint for smooth application.
Paint is drawn from the tank through the hose. The electric spray mechanism converts liquid
paint into fine droplets. Uniform paint is applied onto the wall surface. The use of a spray gun
significantly reduces painting time compared to conventional roller methods.
The driving mechanism is made compact and simple and fitted in the gap between the frame
and the wheel, making it possible to make a wheel of a simple structure providing forward
efficiency at low cost. According to this, a wheel with an operation lever is provided which
makes that is easy to reciprocate for moving the wheel forward.
As we can see it has free wheel which acts as one-way ratchet and driver by operating the liver
by pull action which propels the chair. The lever pulling action
CHAPTER 6
6.1 Results
The painting tool achieved consistent and uniform paint coating on flat surfaces. Paint
thickness variation was minimal compared to manual painting. Painting time was reduced by
30–50% compared to manual methods.
6.2 Advantages
6.3 Disadvantages
Expensive to purchase, install, and integrate
6.4 Limitations
Cannot easily handle unknown or changing surface conditions without advanced
vision systems
6.5 Applications
Painting car bodies, doors, bumpers, and chassis
Used where human painting is unsafe (toxic fumes, high temperature, explosive zones)
CHAPTER 7
7.1 Conclusion
The technique of remote operating 3-axis spray painting machine is presented here which
shows better supplementation between man & machine. The IR sensor is used to detect
presence of wall & also to adjust the distance between wall and machine. In the future, we
would like to expand features & application of the painting robot by using image processing in
order to scan the objects and obstruction that are present in the wall so that the painting can be
completed in graceful manner.
Virtual simulation of painting process before actual execution. Improves accuracy and reduces
errors. Reduced Cost & Wider Adoption. Lower hardware and software costs in future.
Increased adoption in MSMEs and start-ups.
CHAPTER 8
8.1 Summary
To the best of our knowledge, all of the existing indoor paint robots have a low (1.7 m) or
average (3 m) reach access and are not capable of delivering desirable functionality for high-
rise warehouses within a stand-alone system. Moreover, the previous works relied on the two-
dimensional (2-Drange measurements by creating a 2-D map of walls to locate the robot’s
position, which is only suitable for painting flat surfaces. The implementation of three-
dimensional (3-Denvironment perception and robot–human collaboration in construction
painting robots are not well studied in other works to deal with uncertainties in the build
environment and errors in mobile robot positioning, and to paint walls with indentations or
protrusions. The computer-aided design(CAD) model-based planning approaches previously
deployed by conventional painting robots do not properly fit the interior finishing task due to
the existence of less stringent 3-D models as well as the errors of mobile robot positioning. The
traditional paint robots used in other industries, including manufacturing, automobile, and so
on, are not meant to be operated with anyone nearby, and they can apply paint to objects with
a precise CAD model (i.e., cars) that are fixed, relative to the robotic painters.
The robotic painter could work safely in close proximity to human co-workers performing the
repetitious and troublesome task of painting at high elevations. The tool provides a way to
combine the benefits of automation in construction with those of human dexterity and
ingenuity. Thus, it relieves workers of the tiresome tasks and considerable climbing, bending,
kneeling, and reaching, freeing them to paint walls at low heights and supervise the robot. By
utilizing a modular system, the robot is designed as a stand-alone system with six primary
subsystems: a 3-DoF mobile robot, a 1-DoF long-reach jump mechanism, a 6-DoF industrial
robot arm, an airless paint pump, a painting head system, and a computer-controlled system.
The tool is outfitted with a sensor-driven painting system via spray-gun motion planning, which
adapts to the uncertainties of inherent in construction environments and robot deployments
from various positions. Moreover, we employ human perception to decompose a broad
functional area to smaller workspaces and to position the robot at approximately anticipated
locations with the help of both visual and data feedbacks.
8.2 References
3. Rajesh Kannan Megalingam, Vineeth Prithvi Darla, Chaitanya Sai Kumar Nimmala.
An Autonomous wall painting robot. 2020 International conference for emerging
technology (INCET), 1-6, (2020). [Link]
Kannan
Megalingam/publication/342170537_Autonomous_Wall_Painting_Robot/links/5ee72
2bd458515814a5e9daf/[Link]
4. Abdulrahman Yahya, Raed Abdulla, Syed Mohd Bahrin. An Automatic wall painting
robot with multiple colours. Journal of Applied Technology and Innovation (e-ISSN:
2600-7304) 4 (3), 1,
(2020).[Link]
tomatic_Wall_P ainting_Robot_with_Multiple_Co
lors/links/66ed711ffc6cc4648965a579/Automatic-WallPainting-Robot-
[Link]
[Link]
matic_p ainting_mobile_robot_2021.pdf
9. Ponnandithaa Pillai, Sakshi Chonkar, Prashant Kharote. Robot paint-the proposed wall
painting robot: A unified control system integrating hardware and software for efficient
operation. 2024 IEEE 9th International Conference for Convergence in Technology
(I2CT), 1-5, (2024).
[Link]
10. A Jaya Mabel Rani, A Sumalatha, S Annie Angeline Preethi, R Indhu, M Jayaprakash,
M Preetha. Innovations in robotic technology: A smart robotic design for effortless wall
painting using artificial intelligence. 2024 International Conference on Automation and
Computation(AUTOCOM), 267-271, (2024).
[Link]
14. Ayman Abdullah Ahmed Al Mawali, Shaik Mazhar Hussain. Automated wall painting
robot for mixing colours based on mobile application. International Journal of
Engineering and Manufacturing 13 (1), 33, (2023).
[Link]
17. S Jeya Mary, S Sajithra, G Divya, Pallavi Giri, K Al-Qawasmi. NextGen Robot: An
Efficient and Effortless Wall Painting Robot Design Based on Artificial Intelligence
(AI) Principles. 2024 International Conference on Innovative Computing, Intelligent
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[Link]