高壓無氣噴塗技術因能在不依靠壓縮空氣的情況下完成高效率的塗料霧化，且適用於高黏度與高固含量塗料，已被廣泛應用於大型鋼構、橋樑與儲存桶槽等防蝕工業塗裝作業。然而，傳統人工噴塗在面對大型桶槽或高處結構時，往往需要作業人員進入高空或懸吊作業環境，存在墜落、吸入有害揮發物等安全風險。因此近年來，爬壁式噴塗機器人逐漸成為替代人力的解決方案，不僅能提供穩定且一致的塗層品質、降低人為造成的覆蓋不均與塗料浪費，更可顯著減少作業人員暴露於高風險環境中所可能引發的工安事故。而在實務上透過機器人的噴塗時，發現到在實際高壓無氣噴塗過程中，由於高壓驅動產生的高動能，仍可能導致大量塗料粒子於飛行及撞擊表面後發生逸散，不僅造成塗料浪費與環境污染，也降低沉積效率與成膜品質的穩定性。因此，本研究以爬壁式噴塗機器人在桶槽表面塗裝作業為主要應用場景，針對其製程與風罩結構設計進行逸散控制的優化研究，並結合數值模擬與實驗量測的方式，首先確認建立之數值模型與實驗的準確性，再探討風罩幾何、吹氣與抽氣設計對粒子逸散之影響。最後，進一步針對實務應用中噴塗機器人所搭配之實體風罩幾何進行模擬，並引入真實油漆材料性質，使模擬條件更貼近實際高壓無氣噴塗製程，提升數值分析對實際工業應用的參考價值。
在數值模擬方面，建立與實驗相同的三維幾何模型，並採用 Realizable k-ε紊流模型與離散相模型(Discrete Phase Model)模擬噴嘴噴塗、粒子霧化、飛行、碰撞與逸散等完整過程，系統性探討不同風罩幾何、吹氣與抽氣設計對粒子附著與逸散行為的影響。透過改變不同製程條件如吹氣角度、抽氣角度、抽氣孔形狀，觀察風罩內部流場中，氣體的走向和其導引能力與粒子軌跡的變化，比較各組條件下之壁面沉積率、風罩附著率與逸散率三個指標。結果顯示，當吹氣角度為 60° 且抽氣孔形狀為圓孔時，可最有效減少粒子從風罩間隙逸出，降低整體逸散率。
實驗部分則搭建透明風罩平台並配置質量收集裝置，量測不同條件下粒子在壁面、罩內與罩外的分布情況，以驗證模擬結果的準確性與可行性。結果證實，所建立的模擬架構能有效預測實際粒子分佈趨勢，並提供定量化依據作為逸散控制設計的優化基礎。
本研究之創新與貢獻包括：(1) 以爬壁式噴塗機器人在桶槽表面塗裝應用為目標，提出製程與結構設計優化方向；(2) 結合數值與實驗驗證，提升模型可信度；(3) 導入完整風罩結構與實際製程條件，使研究結果貼近工業應用需求；(4) 建立一套可應用於自動化噴塗系統與實體風罩設計之逸散控制優化流程。此成果可為未來高效率噴塗設備與自動化塗裝系統設計提供重要參考依據。

High-pressure airless spraying efficiently atomizes high-viscosity, high-solids coatings without compressed air, widely used for large steel structures, bridges, and tanks. Manual spraying of such structures poses safety risks, while wall-climbing spray robots offer stable quality, reduced overspray, and improved safety.
In practice, the high kinetic energy of the spray still causes particle escape, wasting material and reducing efficiency. This study focuses on optimizing overspray control for wall-climbing spray robots through process and hood design. A validated CFD model, using the Realizable k-ε turbulence model and Discrete Phase Model, simulates atomization, particle motion, and escape. Variables such as hood geometry, blowing angle, exhaust angle, and exhaust port shape are tested.
Results show that a 60° blowing angle with circular exhaust ports best reduces dispersion. Experiments with a transparent hood confirm simulation accuracy, making the model a reliable tool for process optimization. The study provides a practical framework for improving industrial spray robot performance and coating efficiency.
The main contributions of this work are: (1) targeting wall-climbing spray robots for tank coating to propose process and structural optimization strategies; (2) integrating simulation and experiments to enhance model reliability; (3) incorporating real hood geometry and process conditions to match industrial applications; and (4) establishing an overspray control optimization framework applicable to automated spraying systems and hood design. These findings offer valuable guidance for developing efficient spraying equipment and automated coating systems.

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