Electrostatic spraying system for lead product surface treatment

Abstract

The invention discloses an electrostatic spraying system for lead product surface treatment, relates to the technical field of lead product surface treatment, and aims to solve the problem that a traditional single spraying mode is difficult to meet modern production requirements. The electrostatic spraying system comprises a spraying device, a spray gun rotating device, a control subsystem and a curing device; the spraying device comprises at least four independently-controlled electrostatic spray guns, and each electrostatic spray gun is provided with an independent adjusting mechanism to adjust the spraying position and angle. The workpiece rotating device is used for driving a lead product to rotate and comprises a base, a rotating shaft and a fixing clamp. The spray gun rotating device is used for driving an electrostatic spray gun to rotate around a workpiece and comprises an annular rail frame and a driving mechanism. And the control subsystem is used for generating a spraying path and controlling the spraying device, the spray gun rotating device and the curing device to operate. The method has the advantage that the coating efficiency and the coating quality of the lead product are improved.

Description

Technical Field

[0001] This invention relates to the field of lead product surface treatment technology, and more specifically, to an electrostatic spraying system for lead product surface treatment. Background Technology

[0002] Electrostatic spraying for lead product surface treatment is a process that uses an electrostatic spray gun to charge powder coating, which is then uniformly adhered to the lead product surface using the principle of electrostatic adsorption. Spraying lead products serves two purposes: firstly, it enhances their corrosion resistance, as lead readily reacts chemically with oxygen and moisture in the air, and spraying forms a protective barrier to isolate corrosive media; secondly, it improves their appearance and texture, allowing for diverse colors and gloss levels through the selection of different coatings and spraying processes; and thirdly, it enhances their wear resistance, meeting the wear-resistant requirements of lead products in various usage scenarios. However, the current traditional single spraying method can hardly meet the needs of modern production, especially in terms of coating efficiency and coating quality.

[0003] In terms of coating efficiency, the single-spray-gun operation mode is too time-consuming when dealing with large lead components or mass production, especially for lead products with complex geometries, requiring frequent adjustments to the spray gun position, which prolongs the production cycle. Regarding coating quality control, traditional methods struggle to ensure uniform coating of special areas such as corners and grooves on lead products. For example, uneven coating thickness often occurs in the gaps of lead radiator fins, and uneven electrostatic field distribution can easily cause differences in powder deposition, resulting in inconsistent coating adhesion. Therefore, we propose an electrostatic spraying system for lead product surface treatment. Summary of the Invention

[0004] The purpose of this invention is to provide an electrostatic spraying system for surface treatment of lead products, which aims to solve the problem that traditional single spraying methods can no longer meet the needs of modern production.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: an electrostatic spraying system for surface treatment of lead products, the electrostatic spraying system comprising a spraying device, a spray gun rotation device, a control subsystem, and a curing device; The spraying device includes at least four independently controlled electrostatic spray guns, each equipped with an independent adjustment mechanism to adjust the spraying position and angle; The workpiece rotation device is used to drive the lead product to rotate, and includes a base, a rotating shaft and a fixing fixture; The spray gun rotating device is used to drive the electrostatic spray gun to rotate around the workpiece, including a ring track frame and a drive mechanism; The control subsystem is used to generate the spraying path and control the operation of the spraying device, the spray gun rotation device, and the curing device. The curing device is used for high-temperature curing of the sprayed workpiece.

[0006] Preferably, the electrostatic spray gun head is made of aluminum alloy that can stably generate an electrostatic field, and is equipped with a high-voltage electrostatic generator. The powder coating adheres to the surface of the lead product through electrostatic adsorption. The control subsystem generates the motion trajectory of the electrostatic spray gun based on a spray path optimization algorithm. This algorithm calculates the optimal spray spacing using the following formula:

[0007] in, The optimal distance between the electrostatic spray gun and the workpiece surface. This is the material correction factor. The surface area of ​​the workpiece. For the density of powder coating, For the spray gun movement speed, The electrostatic field strength is... The value represents the powder deposition efficiency, ranging from 0.6 to 0.9.

[0008] Preferably, the annular track frame in the spray gun rotating device is arranged around the workpiece rotating device, and the electrostatic spray gun moves circumferentially along the annular track frame via a mounting bracket. The driving mechanism is a servo motor.

[0009] Preferably, the electrostatic spraying system employs an adaptive electrostatic field strength adjustment model during multi-layer spraying, and the field strength distribution calculation formula is as follows:

[0010] in, Let be the real-time field strength at spatial coordinates (x, y, z). This is the initial field strength setting value. For the first The weighting coefficients for the coating layers are 0.7 for the bottom layer and 0.3 for the top layer. From coordinates (x, y, z) to the th The distance between the surfaces of the coating layers The comprehensive influence factor for multi-layer coatings ranges from 1.5 to 2.5.

[0011] Preferably, the electrostatic spraying system further includes a high-efficiency waste gas treatment device for treating the waste gas generated during spraying and reducing VOC emissions.

[0012] Preferably, the curing device includes a curing oven, a heating module, and a temperature control module. The heating module can raise the temperature inside the curing oven to 150℃-250℃, and the temperature control accuracy is ±2℃.

[0013] Preferably, the electrostatic spraying system can flexibly select or combine rotary spraying and reciprocating spraying methods according to the shape of the workpiece and the coating requirements. Rotary spraying is achieved by rotating the workpiece and rotating the spray gun around the workpiece, while reciprocating spraying is achieved by making the spray gun move back and forth in a certain area.

[0014] Preferably, when the electrostatic spraying system is applied to multi-layer spraying, the bottom layer coating uses epoxy resin or polyester-reinforced coating to improve hardness, wear resistance and scratch resistance, and the top layer coating uses environmentally friendly powder coating with high gloss to meet appearance requirements.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention achieves multi-dimensional automated spraying by having at least four independently controlled electrostatic spray guns work together, coupled with an independent adjustment mechanism that can adjust the spraying position and angle, a ring track frame for the spray gun rotation device and a servo motor drive, and a workpiece rotation device that drives the lead product to rotate. This avoids the time-consuming problem of frequent position adjustments when a single spray gun is facing large components or complex-shaped workpieces. At the same time, the control subsystem calculates the optimal spraying spacing based on the spraying path optimization algorithm, reducing ineffective movement and significantly shortening the spraying time for mass production or complex workpieces.

[0016] 2. This invention employs an aluminum alloy electrostatic spray gun head and an internal high-voltage electrostatic generator to stably generate an electrostatic field to ensure uniform powder adsorption. Combined with an adaptive adjustment model for electrostatic field strength during multi-layer spraying, the field strength distribution is dynamically adjusted based on the differences between the bottom and top layers, combined with the distance from spatial coordinates to each layer and comprehensive influencing factors. This effectively improves the problem of uneven electrostatic field in special areas such as corners and grooves of lead products, avoids differences in powder deposition, and ensures uniform coating thickness and consistent adhesion.

[0017] 3. This invention flexibly combines rotary spraying and reciprocating spraying methods according to the shape of the workpiece and the coating requirements, adapting to the coating needs of lead products with different geometric shapes. At the same time, when spraying multiple layers, the bottom layer uses epoxy resin or polyester reinforced coating to improve hardness and wear resistance, and the top layer uses high-gloss environmentally friendly powder coating to meet appearance requirements. Through the adaptation of materials and processes, the coating adaptability of lead products in different usage scenarios is enhanced. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the electrostatic spraying system in this invention. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Example

[0020] An electrostatic spraying system for surface treatment of lead products, the electrostatic spraying system includes a spraying device, a spray gun rotation device, a control subsystem and a curing device; The spraying device includes at least four independently controlled electrostatic spray guns, each equipped with an independent adjustment mechanism to adjust the spraying position and angle. The independent control and adjustment of multiple electrostatic spray guns covers a larger spraying area, reduces the frequency of electrostatic spray gun position adjustment, and improves the spraying efficiency of complex-shaped workpieces. The workpiece rotation device is used to drive the lead product to rotate. It includes a base, a rotating shaft and a fixed fixture. The workpiece rotation is combined with the movement of the electrostatic spray gun to achieve 360° spraying without dead angles. It is especially suitable for workpieces with complex geometries and ensures uniform spraying. The spray gun rotation device is used to drive the electrostatic spray gun to rotate around the workpiece. It includes a ring track frame and a drive mechanism. The rotation of the electrostatic spray gun around the workpiece can expand the spray coverage area. Combined with the rotation of the workpiece, it forms a multi-dimensional spray path and improves the spraying efficiency of large components. The control subsystem is used to generate the spraying path and control the operation of the spraying device, spray gun rotation device and curing device to avoid errors caused by human intervention and improve spraying efficiency and consistency. The curing device is used to cure the sprayed workpiece at high temperature, ensuring that the coating is tightly bonded to the workpiece surface and improving the coating's hardness, wear resistance and other properties.

[0021] Furthermore, the electrostatic spray gun head is made of aluminum alloy, which can stably generate an electrostatic field. It contains a high-voltage electrostatic generator and uses electrostatic adsorption to adhere the powder coating to the surface of the lead product. The control subsystem generates the electrostatic spray gun's trajectory based on a spray path optimization algorithm. This algorithm calculates the optimal spray spacing using the following formula:

[0022] in, The optimal distance between the electrostatic spray gun and the workpiece surface. This is the material correction factor. The surface area of ​​the workpiece. For the density of powder coating, For the spray gun movement speed, The electrostatic field strength is... The powder deposition efficiency is set at 0.6-0.9. An aluminum alloy material and a high-voltage electrostatic generator are used to ensure a stable electrostatic field. Combined with an optimization algorithm to calculate the optimal spraying spacing, powder deposition can be precisely controlled, avoiding uneven coating thickness caused by improper spacing and improving coating quality.

[0023] Furthermore, the annular track frame in the spray gun rotation device is set around the workpiece rotation device. The electrostatic spray gun moves circumferentially along the annular track frame through the mounting bracket. The driving mechanism is a servo motor. The servo motor drives the annular track frame to achieve precise circular motion of the electrostatic spray gun. It works in conjunction with the workpiece rotation to form a standardized spraying path, improving spraying efficiency and uniformity, and is especially suitable for mass production.

[0024] Furthermore, the electrostatic spraying system employs an adaptive electrostatic field strength adjustment model during multi-layer spraying, and the formula for calculating the field strength distribution is as follows:

[0025] in, Let be the real-time field strength at spatial coordinates (x, y, z). This is the initial field strength setting value. For the first The weighting coefficients for the coating layers are 0.7 for the bottom layer and 0.3 for the top layer. From coordinates (x, y, z) to the th The distance between the surfaces of the coating layers The comprehensive influence factor for multi-layer coatings is set to 1.5-2.5. An adaptive adjustment model dynamically adjusts the field strength according to the coating thickness and location. The weights of the bottom layer and the top layer are set differently. This can solve the problem of powder deposition differences caused by uneven field strength in corners, grooves and other parts of lead products, and ensure the uniformity and adhesion of multi-layer coatings.

[0026] Furthermore, the electrostatic spraying system also includes a high-efficiency exhaust gas treatment device to treat the exhaust gas generated during spraying, reduce VOC emissions, meet environmental protection requirements, and improve the working environment.

[0027] Furthermore, the curing device includes a curing oven, a heating module, and a temperature control module. The heating module can raise the temperature inside the curing oven to 150℃-250℃, with a temperature control accuracy of ±2℃. This precise temperature control ensures that the powder coating is fully cured, avoiding coating performance defects caused by temperature deviations, while also reducing energy waste.

[0028] Furthermore, the electrostatic spraying system can flexibly select or combine rotary spraying and reciprocating spraying methods according to the shape of the workpiece and the coating requirements. Rotary spraying is achieved by rotating the workpiece and rotating the spray gun around the workpiece, while reciprocating spraying is achieved by making the spray gun move back and forth in a certain area. With diverse spraying methods, different workpiece shapes can be adapted to each other. Flexible combination can optimize spraying efficiency and accuracy and meet personalized coating needs.

[0029] Furthermore, when electrostatic spraying systems are applied to multi-layer spraying, the base coat uses epoxy resin or polyester-reinforced coatings to improve hardness, wear resistance, and scratch resistance, while the top coat uses environmentally friendly powder coatings with high gloss to meet appearance requirements. By differentiating between the base and top coats, the base coat enhances performance, while the top coat improves appearance, balancing functionality and decoration, thus expanding application scenarios.

[0030] The embodiments disclosed in this invention are preferred embodiments, but are not limited thereto. Those skilled in the art can easily understand the spirit of this invention based on the above embodiments and make different extensions and variations, but as long as they do not depart from the spirit of this invention, they are all within the protection scope of this invention.

Claims

1. An electrostatic spraying system for surface treatment of lead products, characterized in that, The electrostatic spraying system includes a spraying device, a workpiece rotation device, a spray gun rotation device, a control subsystem, and a curing device; The spraying device includes at least four independently controlled electrostatic spray guns, each equipped with an independent adjustment mechanism to adjust the spraying position and angle; The workpiece rotation device is used to drive the lead product to rotate, and includes a base, a rotating shaft and a fixing fixture; The spray gun rotating device is used to drive the electrostatic spray gun to rotate around the workpiece, including a ring track frame and a drive mechanism; The control subsystem is used to generate the spraying path and control the operation of the spraying device, the spray gun rotation device, and the curing device. The curing device is used for high-temperature curing of the sprayed workpiece.

2. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, The electrostatic spray gun head is made of aluminum alloy, which can stably generate an electrostatic field. It contains a high-voltage electrostatic generator and uses electrostatic adsorption to adhere the powder coating to the surface of the lead product. The control subsystem generates the electrostatic spray gun's trajectory based on a spray path optimization algorithm. This algorithm calculates the optimal spray spacing using the following formula: in, The optimal distance between the electrostatic spray gun and the workpiece surface. This is the material correction factor. The surface area of ​​the workpiece. For the density of powder coating, For the spray gun movement speed, The electrostatic field strength is... The value represents the powder deposition efficiency, ranging from 0.6 to 0.

9.

3. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, The annular track frame in the spray gun rotating device is set around the workpiece rotating device, and the electrostatic spray gun moves around the annular track frame via a mounting bracket. The driving mechanism is a servo motor.

4. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, The electrostatic spraying system employs an adaptive electrostatic field strength adjustment model during multi-layer spraying, and its field strength distribution calculation formula is as follows: in, Let be the real-time field strength at spatial coordinates (x, y, z). This is the initial field strength setting value. For the first The weighting coefficients for the coating layers are 0.7 for the bottom layer and 0.3 for the top layer. From coordinates (x, y, z) to the th The distance between the surfaces of the coating layers The comprehensive influence factor for multi-layer coatings ranges from 1.5 to 2.

5.

5. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, The electrostatic spraying system also includes a high-efficiency exhaust gas treatment device for treating the exhaust gas generated during spraying and reducing VOC emissions.

6. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, The curing device includes a curing oven, a heating module, and a temperature control module. The heating module can raise the temperature inside the curing oven to 150℃-250℃, and the temperature control accuracy is ±2℃.

7. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, The electrostatic spraying system can flexibly select or combine rotary spraying and reciprocating spraying methods according to the shape of the workpiece and the coating requirements. Rotary spraying is achieved by rotating the workpiece and rotating the spray gun around the workpiece, while reciprocating spraying is achieved by making the spray gun move back and forth in a certain area.

8. The electrostatic spraying system for surface treatment of lead products according to claim 1, characterized in that, When the electrostatic spraying system is applied to multi-layer spraying, the bottom layer uses epoxy resin or polyester-reinforced coatings to improve hardness, wear resistance and scratch resistance, and the top layer uses environmentally friendly powder coatings with high gloss to meet appearance requirements.

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