An automated gasket zinc-aluminum coating process

Abstract

The application discloses an automatic gasket zinc-aluminum coating process, wherein a robot is used for gasket feeding, discharging and transfer operation in and between processes, so that the gasket to be treated is sequentially subjected to the following process treatment: (1) degreasing and oil removing treatment; (2) shot blasting rust removing treatment; (3) zinc-aluminum coating immersion; (4) low-temperature preheating separation; (5) high-temperature baking and curing; and (6) cooling. The gasket feeding, discharging, process transfer and coating operation in each process are realized by the robot, so that the work efficiency is effectively improved, and the cost is reduced; the low-temperature preheating achieves a micro-drying state without chemical reaction, then separation is realized, and then curing is realized, so that the coating effect and product quality are improved, the appearance quality of the coated gasket is good, and defects such as adhesion and lap are avoided, and the gasket performance is excellent.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of gasket coating, in particular to an automatic gasket zinc-aluminum coating process. BACKGROUND

[0002] A gasket is a mechanical seal between two objects, usually to prevent leakage from or ingress into the packed area due to the pressure difference, corrosion and natural thermal expansion and contraction of the pipeline. Since the machined surface cannot be perfect, the use of gaskets can fill in the irregularities. Metal gaskets are the most commonly used gaskets in existing mechanical equipment, such as planetary gaskets. In order to improve the performance of the gasket, such as corrosion resistance, durability, sealing, etc., the industry usually needs to coat the metal gasket.

[0003] At present, gasket coating basically uses manual brushing. Manual brushing inevitably has the following problems:

[0004] 1. Coating quality is unstable, with problems such as sticking, overlapping, missing coating, poor salt spray performance, etc., which cannot guarantee product quality;

[0005] 2. Multiple rework is required during the coating process, causing resource waste, reducing production efficiency, and low product forming rate. For example, in order to meet the salt spray requirements, even repeated brushing is required, which causes a large amount of powder to fall off during gasket assembly, serious bruising, etc. In addition, multiple coating processes can also cause unsatisfactory gasket adhesion; for gaskets with sticking, only the sticking products can be manually selected and thrown away for rework; for gaskets with overlapping, forced separation can also cause damage to the paint film. SUMMARY

[0006] The present application provides an automatic gasket zinc-aluminum coating process, which can solve the above-mentioned problems in the prior art manual / artificial coating.

[0007] To solve the above technical problems, the present application provides an automatic gasket zinc-aluminum coating process, which uses a robot for gasket feeding, discharging and transfer operation between processes. The gaskets to be treated are sequentially processed as follows:

[0008] (1) degreasing and oil removal treatment;

[0009] (2) shot blasting and rust removal treatment;

[0010] (3) zinc-aluminum coating, placing the gaskets after shot blasting and rust removal treatment in step (2) in a hollow frame, then immersing the gaskets and the hollow frame together into a pool containing zinc-aluminum coating solution using the robot, so that the surface of the gaskets is immersed and coated with a zinc-aluminum coating;

[0011] (4) low-temperature preheating separation: the robot is used to pour the gasket in the hollow frame after immersion into the upper conveying belt of the heating forming device, and the gasket is conveyed to the preheating box section of the heating furnace for low-temperature preheating, so that the zinc-aluminum coating solution on the surface of the gasket is slightly dry and does not undergo chemical cross-linking reaction, and then the gasket is continuously conveyed to naturally drop onto the lower conveying belt;

[0012] (5) high-temperature baking and curing: the gasket is conveyed to the high-temperature box section of the heating furnace along with the lower conveying belt for baking and curing to complete the cross-linking reaction;

[0013] (6) the gasket after completing the curing is conveyed to outside of the heating furnace along with the lower conveying belt, cooled and cooled to obtain the gasket coated with zinc-aluminum coating.

[0014] In a preferred embodiment of the present application, the robot is a 6-axis robot controlled by a DKL-2025 intelligent cloud recognition system.

[0015] In a preferred embodiment of the present application, in the step (3), the loading amount of the gasket in the hollow frame is less than 15 kg.

[0016] In a preferred embodiment of the present application, in the step (3), the viscosity of the zinc-aluminum coating solution is 15-30 Pa·s.

[0017] In a preferred embodiment of the present application, in the step (4), the preheating temperature is 30-60℃.

[0018] In a preferred embodiment of the present application, in the step (4), the robot pours the gasket in the hollow frame onto the upper conveying belt for multiple times, and spreads the gasket after each pouring.

[0019] In a preferred embodiment of the present application, the heating forming device comprises a heating box, a first conveying belt and a second conveying belt; wherein the heating box comprises a preheating box section and a high-temperature box section, one end of the first conveying belt is located outside the heating box, and the other end is located in the preheating box section of the heating box; the second conveying belt is located below the first conveying belt, and the second conveying belt penetrates through the heating box, and both ends of the second conveying belt are located outside the heating box.

[0020] In a preferred embodiment of the present application, the degreasing and oil removing process comprises the steps of centrifugal oil removal, degreasing agent degreasing, high-pressure water rinsing and centrifugal drying.

[0021] In a preferred embodiment of the present application, the process conditions of the degreasing agent degreasing are as follows: the degreasing agent temperature is 50-70℃, the degreasing time is less than or equal to 220 s, and the pH value of the degreasing agent is 7-9.

[0022] In a preferred embodiment of the present application, the process conditions of the shot blasting rust removal process are: shot blasting time 12-24 min, and steel shot diameter 0.3 mm.

[0023] The present application has the advantages that: the automatic gasket zinc-aluminum coating process can realize gasket feeding, discharging and transfer between processes by a robot, effectively improving the work efficiency and reducing the cost; through low-temperature preheating, the gasket is in a micro-dry state without chemical reaction, then separated and solidified, improving the coating effect and product quality, and the appearance quality of the coated gasket is good without defects such as adhesion and offset, and the gasket performance is excellent. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 is a process flow diagram of the automatic gasket zinc-aluminum coating process of the present application;

[0025] Figure 2 is a sectional structure schematic diagram of the heating forming device;

[0026] The labels of the components in the drawings are as follows:

[0027] 10 heating box, 11 preheating box section, 12 high-temperature box section; 20 first conveying belt, 30 second conveying belt. DETAILED DESCRIPTION

[0028] The preferred embodiment of the present application is described in detail below, so that the advantages and features of the present application can be more easily understood by those skilled in the art, and the protection scope of the present application is more clearly defined.

[0029] Example 1

[0030] The DKL-2025 intelligent cloud recognition system is used to control the 6-axis robot to operate the planetary gasket in the feeding, discharging, and transfer operation between processes, and the specific coating operation includes the following processes:

[0031] (1) degreasing and oil removal treatment: the planetary gasket is placed in a centrifugal frame, most of the oil on the surface of the gasket is removed by a centrifugal oil removal dryer, then a weak alkaline degreasing agent is used to high-pressure flush the gasket in the centrifugal frame, in the high-pressure flushing process, the pH value of the degreasing agent is 8, the temperature is 60℃, the centrifugal speed of the centrifugal frame is controlled at 20 r / min, the degreasing time is 180 s, after the degreasing agent is flushed, the same pressure of clean water is used for high-pressure flushing, and finally the planetary gasket after the above treatment is transferred to a drying box and centrifugally dried at 100 r / min.

[0032] (2) Shot blasting treatment, using DKL-2025 intelligent cloud recognition system to control 6-axis robot to put the planet gasket after the above degreasing and drying into the drum-type shot blasting machine, select steel shot with a diameter of 0.3mm as the shot blasting steel shot, then set the shot blasting time according to the strength of the gasket, the higher the strength of the gasket, the longer the shot blasting time, specifically, the strength of the planet gasket of the embodiment is 10.9 grade, and the shot blasting time is set to 20min. The purpose of rust removal of the gasket is achieved by shot blasting. The shot blasting treatment by the drum-type shot blasting machine can effectively reduce the damage to the gasket caused by extrusion and collision, improve the shot blasting quality, and the drum-type shot blasting machine is not easy to jam during operation.

[0033] (3) Coating zinc-aluminum coating, the planet gasket after the above shot blasting is loaded into a hollow frame, the loading capacity of each frame is controlled to be 10kg, then the planet gasket is immersed into a pool containing zinc-aluminum coating liquid with a viscosity of 10Pa·s together with the hollow frame, so that the surface of the planet gasket is coated with the zinc-aluminum coating liquid by immersion coating. Since the gasket has a large plane, it is easy to stick, overlap and miss coating, therefore the loading capacity needs to be controlled to be less than 15kg.

[0034] (4) Low-temperature preheating separation: the planet gasket after immersion in step (3) is grabbed by the robot together with the hollow frame, then the planet gaskets in the hollow frame are poured into the upper conveying belt of the heating forming device in two times and spread thinly to prevent sticking between the gaskets; the upper conveying belt conveys the planet gaskets to the preheating box section of the heating furnace, the temperature in the preheating box section is controlled to be 30℃, so as to realize the preheating treatment of the planet gaskets, so that the zinc-aluminum coating liquid on the surface of the planet gaskets is slightly dry without chemical reaction, then the planet gaskets naturally fall onto the lower conveying belt during the conveying process by the upper conveying belt, completing the separation between the gaskets, preventing sticking and overlapping between the gaskets during the later solidification process.

[0035] Specifically, the heating forming device comprises a heating box 10, a first conveying belt 20 and a second conveying belt 30. The heating box 10 comprises a preheating box section 11 and a high-temperature box section 12. One end of the first conveying belt 20 is located outside one end of the preheating box section 11 of the heating box 10, and the other end is located in the preheating box section 11 of the heating box 10. The second conveying belt 30 is located below the first conveying belt 20, and the second conveying belt 20 penetrates through the heating box 10, with both ends extending out of the heating box 10 and located outside the heating box 10, as shown in Figure 2 .

[0036] (5) High-temperature baking curing: the planet pad falling onto the lower conveying belt is transported to the high-temperature box section of the heating furnace along with the lower conveying belt, the temperature in the high-temperature box section is controlled at 250°C, the zinc-aluminum coating liquid on the surface of the pad is reacted and cured in a slightly dry state, so as to achieve the required adhesion and firmly adhere to the surface of the pad.

[0037] (6) Cooling: the planet pad after curing is transported out of the heating furnace along with the lower conveying belt, and the pad coated with the zinc-aluminum coating is obtained after cooling.

[0038] In the above steps (4) and (5), by controlling the preheating temperature and using the free-fall formed by the multi-layer conveying belt, the problems such as sticking, overlapping and missing coating of the zinc-aluminum coating material during the curing stage can be effectively prevented, thereby effectively improving the coating quality.

[0039] The planet pad coated by the above method has good surface quality of the planet pad after coating, without defects such as sticking and overlapping.

[0040] Example 2

[0041] The DKL-2025 intelligent cloud recognition system is used to control the 6-axis robot to operate the planet pad in each process, including the following processes:

[0042] (1) Degreasing and oil removal treatment: the planet pad is placed in a centrifugal frame, most of the oil on the surface of the pad is removed by a centrifugal oil removal dryer, then a weak alkaline degreasing agent is used to high-pressure rinse the pad in the centrifugal frame, in the process of high-pressure rinsing and degreasing, the pH value of the degreasing agent used is 8, the temperature is 70°C, the centrifugal speed of the centrifugal frame is controlled at 30 r / min, the degreasing time is 180 s, after the degreasing agent is rinsed, the same pressure of clean water is used for high-pressure rinsing, and finally the planet pad after the above treatment is transferred to a drying box and centrifugally dried at 80 r / min.

[0043] (2) Shot blasting and rust removal treatment: the planet pad after the above degreasing and oil removal treatment and drying is placed in a drum-type shot blasting machine by using the DKL-2025 intelligent cloud recognition system to control the 6-axis robot, steel shots with a diameter of 0.3 mm are selected as the shot blasting steel shots, then the shot blasting time is set according to the strength of the pad, the higher the strength of the pad, the longer the shot blasting time, specifically, the strength of the planet pad in this embodiment is 10.9 grade, and the shot blasting time is set to 20 min. The purpose of rust removal of the pad is achieved by shot blasting. The shot blasting and rust removal treatment by using the drum-type shot blasting machine can effectively reduce the damage to the pad caused by extrusion and collision, improve the shot blasting quality, and the drum-type shot blasting machine is also not easy to jam during operation.

[0044] (3) Coating zinc-aluminum coating, loading the planet gasket after the above-mentioned shot blasting into the hollow frame, controlling the loading amount of each frame to be 10 kg, then immersing the planet gasket together with the hollow frame into the pool containing zinc-aluminum coating liquid with a viscosity of 30 Pa·s, so that the planet gasket surface is coated with zinc-aluminum coating liquid by immersion coating. Due to the existence of large plane in the gasket, it is easy to stick, lap and miss coating, etc. Therefore, the loading amount needs to be controlled within 15 kg.

[0045] (4) Low temperature preheating separation: using the above-mentioned robot to pick up the planet gasket after immersion in step (3) together with the hollow frame, then pouring the planet gasket in the hollow frame into the upper conveying belt of the heating forming device in two times and spreading thin to prevent sticking between the gaskets; the upper conveying belt conveys the planet gasket to the preheating box section of the heating furnace, the temperature in the preheating box section is controlled to be 60℃, so as to realize the preheating treatment of the planet gasket, so that the zinc-aluminum coating liquid on the surface of the planet gasket is slightly dry without chemical reaction, then through the conveying process of the upper conveying belt, it naturally falls onto the lower conveying belt, completing the separation between the gaskets, preventing sticking and lapping between the gaskets in the later solidification process.

[0046] (5) High temperature baking and curing: the planet gasket falling onto the lower conveying belt is conveyed to the high temperature box section of the heating furnace together with the lower conveying belt, the temperature in the high temperature box section is controlled to be 270℃, so that the zinc-aluminum coating liquid in the slightly dry state on the surface of the gasket is reacted and cured, so as to achieve the required adhesion and firmly adhere to the surface of the gasket.

[0047] (6) Cooling: the planet gasket after curing is conveyed out of the heating furnace together with the lower conveying belt, and the planet gasket coated with zinc-aluminum coating is obtained after cooling.

[0048] The planet gasket coated by the above-mentioned method has good surface quality without sticking, lap and other defects.

[0049] Example 3

[0050] The difference from example 1 is that in step (3), the viscosity of the zinc-aluminum coating liquid is 20 Pa·s.

[0051] Example 4

[0052] The difference from example 1 is that in step (4), the temperature in the preheating box section is controlled to be 40℃. The planet gasket coated by the above-mentioned method has good surface quality without sticking, lap and other defects.

[0053] Comparative example 1

[0054] The difference from example 1 is that in step (3), the viscosity of the zinc-aluminum coating liquid is 40 Pa·s.

[0055] Because the viscosity of the zinc-aluminum coating liquid used is large, the gaskets are stuck together after entering the upper conveying belt of the heating forming device, and cannot be effectively separated after preheating, so that the finished products have defects such as sticking and overlapping.

[0056] Comparative Example 2

[0057] The difference from Example 1 is that in the step (3), the temperature in the preheating box section is controlled at 65 DEG C.

[0058] Because the preheating temperature is too high, the gaskets are partially crosslinked during the preheating process, and there is a certain solidification between the zinc-aluminum coating liquids on the surfaces of different gaskets, so that the finished products have the defect of overlapping.

[0059] Comparative Example 3

[0060] The difference from Example 1 is that in the step (3), the temperature in the preheating box section is controlled at 25 DEG C.

[0061] Because the preheating temperature is too low, the zinc-aluminum coating liquid on the surface of the gasket cannot form a slightly dry state during the preheating process, so that the gaskets falling onto the lower conveying belt have defects such as missing printing, sticking and overlapping after solidification.

[0062] Comparative Example 4

[0063] The difference from Example 1 is that there is no low-temperature preheating separation, and the gaskets are directly conveyed to the heating box for solidification after being immersed in the zinc-aluminum coating liquid.

[0064] Because there is no low-temperature preheating separation process, the gaskets after solidification have serious defects such as sticking and overlapping, and the yield of finished products is low.

[0065] The planetary gasket coated by the method of the application has good appearance quality, meets the salt fog standard, has no defects such as sticking and overlapping, and improves the competitiveness of the product.

[0066] The DKL-2025 intelligent cloud recognition system is used throughout the process to control the 6-axis robot to perform the gasket zinc-aluminum coating process operation, so that automatic operation and processing are realized, the production efficiency is improved, the manpower is saved, the labor cost is reduced, and the forming rate and coating quality of the product are improved.

[0067] The above only describes the embodiments of the application, and does not limit the patent scope of the application, and any equivalent structure or equivalent process transformation using the content of the application specification, or direct or indirect application in other related technical fields, are also included in the patent protection scope of the application.

Claims

1. An automated gasket zinc-aluminum coating process characterized by, The 6-axis robot is used for loading, unloading and transferring of the gaskets, and the robot is controlled by the DKL-2025 intelligent cloud recognition system, and the gaskets to be processed are sequentially processed in the following processes. (1) degreasing and oil removal treatment; (2) shot blasting rust removal treatment; (3) zinc-aluminum coating immersion, the gaskets after the shot blasting rust removal treatment in step (2) are placed in a hollow frame, and then the robot is used to immerse the gaskets and the hollow frame in a pool containing zinc-aluminum coating liquid, so that the surface of the gasket is immersed and coated with a zinc-aluminum coating; the loading capacity of the gaskets in the hollow frame is less than 15 kg, and the viscosity of the zinc-aluminum coating liquid is 15-30 Pa·s; (4) low-temperature preheating separation: the robot is used to pour the gaskets after immersion in the hollow frame onto the upper conveying belt of the heating forming device, and then the gaskets are conveyed to the preheating box section of the heating furnace for low-temperature preheating to 30-60℃, so that the zinc-aluminum coating liquid on the surface of the gasket is slightly dried without chemical cross-linking reaction, and then the gaskets are continuously conveyed to naturally fall onto the lower conveying belt; the robot pours the gaskets in the hollow frame onto the upper conveying belt in multiple times, and thins out after each pouring; (5) high-temperature baking and curing: the gaskets are conveyed to the high-temperature box section of the heating furnace along with the lower conveying belt for baking and curing to complete the cross-linking reaction; (6) the gaskets after curing are conveyed to the outside of the heating furnace along with the lower conveying belt, cooled and cooled to obtain gaskets coated with zinc-aluminum coating.

2. An automated shim zinc-aluminum coating process according to claim 1, wherein, The heating forming device comprises a heating box, a first conveying belt and a second conveying belt; wherein the heating box comprises a preheating box section and a high-temperature box section, one end of the first conveying belt is located outside the heating box, and the other end is located in the preheating box section of the heating box; the second conveying belt is located below the first conveying belt, and the second conveying belt penetrates through the heating box, and both ends are located outside the heating box.

3. An automated shim zinc-aluminum coating process as defined in claim 1, wherein, The degreasing and oil removal process comprises centrifugal oil removal, degreasing agent degreasing, high-pressure water washing and centrifugal drying steps.

4. An automated shim zinc-aluminum coating process as defined in claim 3, wherein, The process conditions of the degreasing agent degreasing are: degreasing agent temperature 50-70℃, degreasing time less than or equal to 220s, and degreasing agent pH value 7-9.

5. An automated shim zinc-aluminum coating process as defined in claim 1, wherein, The process conditions of the shot blasting rust removal process are: shot blasting time 12-24min, and steel shot diameter 0.3mm.

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