Maximizing the Value of Your Robot Programs

In the Thermal Spray industry, robot programs are essential for applying coatings with consistent microstructure and thickness. Due to complex part geometries and strict customer requirements, developing these programs can take months - with costs often exceeding tens of thousands of dollars.

So, once a successful robot program is achieved on one booth, why not use it on other spray systems?

When and Why Program Reuse is Needed

There are several scenarios where reusing an already approved program becomes necessary:

Spraying the same component in a different spray booth,
Revalidating a program after upgrading booth hardware (robot, turntable, etc.),
Using new fixtures that change the position of the part or spray gun.

Even small differences between systems - like a slight tilt or shift - can cause significant changes in the spray position on the part. While robots are designed to handle such variations, the real challenge lies in how the programs are originally built.

The Challenge of Transferring Robot Programs

Unfortunately, many robot programs in the Thermal Spray industry don't properly utilize essential elements like Tool Centre Points (TCP) and Work Objects, which are often missing or incorrectly configured.

As a result, transferring programs becomes a complex and costly task. Even with a team experienced in the original validation process, redoing it for a new booth often takes just as long and costs just as much.

This complexity discourages many businesses from upgrading their spray booths or validating alternative spray booths, leaving them vulnerable to production delays or failures.

How We Simplify Robot Program Transfers

At EPS-TS, we help you de-risk and accelerate your robot program transfer process. Our proven method can save you months of development time and tens of thousands of dollars.

Here’s how we help:

Review and analyse your critical programs,
Measure and compare key dimensions of your existing and new spray booths,
Correct and optimize your existing programs - without altering their core movements,
Recreate the program on your new system to faithfully replicate the original performance.