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The paper presents a motion planning method of redundant manipulator for painting uniform thick coating on the interior of irregular duct of some aircrafts. Discontinuous peripheral painting method is employed by analyzing the restrictions during painting the duct. For improving the longitudinal uniformity of thick coating, the interlacing painting method plans two sets of sweeping paths and an interlacing distance between the starting paths of the two times of painting. The interlacing distance and overlapping distance are optimized by establishing and analyzing the model of longitudinal uniformity. To enhance the transverse uniformity, sweeping speeds for curved surfaces are calculated by the ratio of transfer efficiency after the basic sweeping speed for the plane is determined. The intertwining method, minimizing the sum of the weighed distances between the duct centerline and key points of the manipulator links, is employed for the joint trajectory planning without collision. The simulation and experiment results show that the redundant manipulators can finish painting the internal surface of the irregular S-shaped duct without collision. The maximum relative deviation is 16.3% and the thicknesses of all measurement points satisfy the acceptance criteria of the factory

Motion Planning of Redundant Manipulators for Painting Uniform Thick Coating in Irregular Duct