This study was performed to validate a simulated model of an automotive factory spray paint gun. The project ensures that repeatable and valid data are obtained in the simulation of a paint process. A simulated paint gun model was created using DELMIA IGRIP simulation software; an interactive, 3D graphic simulation tool for designing, optimizing, and programming robotic paint booths off-line. IGRIP is used to generate optimized robot paths using the workpiece CAD geometry and download robot motion and process programs. A Design of Experiment (DOE) study was executed to validate the simulated paint gun model. The DOE was performed using a physical paint robot and a virtual paint robot. Analysis of Variance (ANOVA) was performed on the two experiments in order to detect any differences in average performance of the paint process parameters tested. Understanding the contribution of each factor was significant to determine the validity of the simulation. The comparison of the outputs of the two experiments provided an assessment and validation of the simulated paint gun model. The IGRIP simulation software is limited in its abilities to quantify expected improvements of all paint quality characteristics in that it is not able to consider parameters of viscosity, humidity, temperature, air velocity. The IGRIP model that was developed must be calibrated to mimic the physical process results. This thesis advances the Simulation and Off-Line Programming project as it supports the development of a robust design for the paint process simulation.
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