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When a reciprocating machine reverses direction at the dead point, how can the servo control smoothly transition to avoid localized coating buildup?

Author: BOSTAR Technical Content CenterTechnical Review: BOSTAR Spray Application Engineering GroupPublished: July 11, 2026Updated: July 11, 2026

Scope: General electrostatic spraying adjustment logic. This does not replace equipment-specific manuals.

The local coating accumulation at the reciprocating position of the reciprocator is usually not caused by a simple "servo stop", but by the joint superposition of the trajectory velocity near the dead point, the continuous output of the spray gun, the repeated coverage of the spray amplitude and the mechanical following error. The correct approach is to use the S-shaped or other smooth trajectory of continuous velocity and continuous acceleration, limit the acceleration and acceleration (Jerk), set the mechanical dead center outside the effective spraying area, and combine the early shutdown of the spray gun, delayed opening, flow compensation with velocity or boundary area trajectory optimization. It is necessary to verify the actual position of the servo, the actual speed, the following error, the workpiece boundary, the conveying line speed and the film thickness grid at the same time, not only the PLC set speed.

The local coating accumulation at the reciprocating position of the reciprocator is usually not caused by a simple "servo stop", but by the joint superposition of the trajectory velocity near the dead point, the continuous output of the spray gun, the repeated coverage of the spray amplitude and the mechanical following error. The correct approach is to use the S-shaped or other smooth trajectory of continuous velocity and continuous acceleration, limit the acceleration and acceleration (Jerk), set the mechanical dead center outside the effective spraying area, and combine the early shutdown of the spray gun, delayed opening, flow compensation with velocity or boundary area trajectory optimization. It is necessary to verify the actual position of the servo, the actual speed, the following error, the workpiece boundary, the conveying line speed and the film thickness grid at the same time, not only the PLC set speed.

The English edition of this article is being prepared. Please refer to the Chinese version linked above, or contact us for engineering support in English.

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