上世纪60年代，美国研制成功第四代F22新型隐身战机，并逐步完善F22吸波特种涂料涂装工艺。而由于国外对新一代战机设计与制造理论和技术，特别是隐身涂装装备、材料和工艺技术方面的严格封锁，我国此方面的研究处于空白。为此，2013年清华大学针对我国新一代型号的制造要求，率先提出了一套根据实际飞机位姿变换原始机器人作业规划的移动机器人喷涂系统，填补了隐身自动化涂装装备空白，并对相应的涂装工艺理论进行了初步探索。但在飞机表面自动化喷涂上漆率与喷涂工艺参数的关系建模、基于上漆率的涂层厚度及其分布模型与工艺参数的定量关系表达、喷涂工艺参数组合优化等决定先进战机隐身涂层性能的喷涂参数建模、评价与工艺优化等理论研究方面仍有待深入。本文通过理论和实验分析，研究飞机表面自动化喷涂工艺参数对喷涂上漆率的影响，首次建立了以喷涂工艺多参数作为自变量的上漆率模型，与传统研究将上漆率作为常量的处理方法相比具有更高的精度。提出了一种基于椭圆高斯分布表达的自动化喷涂涂层厚度分布理论模型，揭示了自动化喷涂工艺参数与涂层厚度及其分布之间的定量关系，结合本文推导的上漆率模型，大幅度提高了涂层厚度及其分布模型的计算精度，并给出了喷涂厚度均匀性评价指标和方法。基于上漆率和涂层厚度理论模型研究，针对飞机表面隐身涂层自动化喷涂典型工艺参数，设计并完成了五因素六水平的正交实验，给出上漆率和涂层厚度分布理论模型的待定系数，提出了一种具有工程应用价值的自动化喷涂涂层厚度分布工艺模型，以解决飞机自动化隐身材料涂覆均匀度问题。考虑飞机表面涂层自动化喷涂搭接工艺对涂层厚度分布的影响，基于模型及其涂层厚度均匀性指标，提出了一种基于工艺参数优化目标函数的喷涂工艺参数组合优化方法，并设计研发了流量精确控制装置，以保证流量控制精度。用该方法指导了实际飞机典型外表面区域的喷涂工艺，其涂层测厚结果验证了理论研究的有效性。

In the 1960s, the fourth-generation stealth fighter-F22 was made in US, and the coating process of F22’s suction paint is gradually improved. However, due to foreign countries' strict blockade on the design and manufacturing theory and technology of new generation fighters, especially stealth coating equipment, materials and technology, our country's research in this area is in a blank. For this reason, in 2013, Tsinghua University took the lead in proposing a mobile robot spraying system based on the original robot operation plan of the actual aircraft’s pose transformation in response to the manufacturing requirements of the new generation stealth fighter in my country, which filled the gaps in stealth coating automated spraying equipment, and responded to the corresponding preliminary explorations of the theory of coating technology. However, some theoretical research aspects still need to be in-depth researched consisting of the performance of spraying parameter modeling, evaluation and process optimization and others. For example, the modeling of the relationship between the paint transfer efficiency(TE) and the spraying process parameters of the automatic spraying on the surface of the aircraft, the quantitative expression of the coating thickness and its distribution model and the process parameters based on the TE, and the optimization of the combination of spraying process parameters. All mentioned above determine the property of the fighter aircraft’s stealth coating. Through theoretical and experimental analysis, this paper studies the influence of aircraft surface automatic spraying process parameters on the TE. For the first time, the TE model with multiple parameters of the spraying process as independent variables is established. Compared with the traditional research that treats the paint rate as a constant, it has higher accuracy.A theoretical model of automatic spray coating thickness distribution based on the expression of elliptical Gaussian distribution is proposed, which reveals the quantitative relationship between the automatic spraying process parameters and the coating thickness and its distribution. Combined with the TE model derived in this paper, it greatly improves the calculation accuracy of the coating thickness and its distribution model, and the evaluation index and method of spray thickness uniformity are given.Based on the study of the theoretical model of paint rate and coating thickness, a five-factor and six-level orthogonal experiment was designed and completed for the typical process parameters of automatic spraying of stealth coating on aircraft surface, and the theoretical model of TE and coating thickness distribution was given. With undetermined coefficients, an automatic spray coating thickness distribution process model with engineering application value is proposed to solve the problem of uniformity of the stealth material coating of aircraft.Considering the influence of the automatic spraying overlap process of aircraft surface coating on the coating thickness distribution, based on the model and its coating thickness uniformity index, a spraying process parameter combination optimization method based on the process parameter optimization objective function is proposed, and a precise paint flow rate control device is designed and installed to ensure the accuracy of paint flow rate control. This method is used to guide the spraying process of the typical outer surface area of the actual aircraft, and the coating thickness measurement results verify the validity of the theoretical research.