High-precision all-dimensional polymer coating spraying system for gear

Abstract

The invention discloses a high-precision all-dimensional polymer coating spraying system for a gear. The high-precision all-dimensional polymer coating spraying system comprises a gear preheating rotating device, a spraying device and a control device. The gear preheating rotating device heats and rotates the gear through the clamp, the heating device and the rotating disc so as to ensure that the gear meets the high polymer material spraying temperature requirement, and the stability of the coating spraying thickness is guaranteed. The spraying device is composed of an air compressor, a spray gun, a spray gun support, a coating pressure tank and a cleaning pressure tank. The spray gun accurately adjusts airflow and coating flow through an electronic control type pressure valve so as to achieve the uniform spraying effect. The control device adopts an industrial-grade PLC (Programmable Logic Controller) or an embedded control system to carry out centralized control on operations such as turntable rotation, gear heating and spray gun spraying. The device comprises a sensor and a control panel, and can monitor the equipment state and operation parameters in real time. By integrating the high-precision spraying function and the heating function, the precision and efficiency of gear coating treatment are remarkably improved through the system.

Description

Technical Field

[0001] The invention relates to the technical field of gear processing, in particular to a high-precision all-round polymer coating spraying system for gears. Background Art

[0002] With the continuous advancement of polymer material technology, the performance of polymer coating materials has been significantly improved, and the demand for their application has also increased. However, the current spraying equipment has limitations in bringing out the performance of these advanced coating materials and fails to fully meet the stringent requirements of modern manufacturing for high-quality coatings. Spraying technology, as a key process, is mainly used to enhance the wear resistance, corrosion resistance and overall performance of gears. However, the current gear spraying technology faces many challenges:

[0003] 1. Complexity of the spraying process: Due to the complexity and irregularity of the gear surface, it is difficult to achieve uniform coverage during the spraying process. Traditional spraying equipment is often not precise enough in controlling the spraying angle and spraying amount, which makes it difficult to ensure the spraying quality.

[0004] 2. Precise control of spraying time and angle: Given the rotational characteristics and shape changes of gears, it is particularly difficult to accurately control the movement trajectory and spraying time of the spray gun during the spraying process. This control difficulty often leads to uneven coating or overspraying in local areas, thus affecting the uniformity and final quality of the coating.

[0005] 3. Challenges in spraying amount control: In existing equipment, the control of the spraying amount of polymer coating materials is often not precise enough. Insufficient spraying amount may result in a coating that is too thin and cannot meet the use standards of the gears; conversely, excessive spraying amount may result in a coating that is too thick, bubbles will be generated during the curing process, and even the coating will be scrapped.

[0006] 4. Insufficient automation: The current gear spraying equipment has a low degree of automation and usually requires a lot of manual intervention and adjustment, which not only increases the complexity of operation, but also increases labor intensity and increases the difficulty of equipment maintenance. Summary of the invention

[0007] The object of the present invention is to provide a high-precision all-round polymer coating spraying system for gears, comprising a gear preheating rotating device, a spraying device and a control device.

[0008] The gear preheating rotating device comprises a fixture, a turntable, a turntable, a heating device, a turntable base, a conductive slip ring, a hyperbolic reducer and a motor connected to the hyperbolic reducer.

[0009] The hyperbolic reducer is equipped with a conductive slip ring and a turntable.

[0010] The turntable is located above the conductive slip ring.

[0011] The slip ring rotor of the conductive slip ring is fixedly connected to the rotating shaft of the turntable, and a turntable base is provided between the conductive slip ring and the turntable. The turntable base is sleeved outside the rotating shaft and is used to support the turntable.

[0012] The turntable is fixed on the turntable and rotates along with the turntable.

[0013] A wire hole is provided at the center of the turntable, and N groups of clamp fixing holes are spaced around the wire hole. N L-shaped clamps for fixing the inner holes of the gears are fixed to the clamp fixing holes of the turntable by bolts, so that the clamps and the gears form an inner cavity for placing the heating device.

[0014] The conductive wire of the conductive slip ring passes through the conductive wire hole and is connected to the heating device to provide power supply for the heating device.

[0015] The spraying device comprises a spray gun, a spray gun bracket, a paint pressure tank and a cleaning pressure tank.

[0016] The spray gun bracket is an adjustable bracket, on which a spray gun is mounted, and the spraying angle of the spray gun is controlled by adjusting the angle of the bracket.

[0017] The paint pressure tank and the cleaning pressure tank are connected to the spray gun to provide paint and cleaning agent to the spray gun.

[0018] The control device comprises a box body and a controller, a sensor, a control valve and a control panel integrated on the box body.

[0019] The heating temperature of the heating device, the rotation speed and rotation direction of the turntable and the spraying pressure of the spray gun can be adjusted by the control device.

[0020] Furthermore, the turntable is provided with a group of clamp fixing holes, and each group of clamp fixing holes is arranged at an interval of 120°.

[0021] Each group of clamp fixing holes includes a plurality of clamp fixing holes, and the clamp fixing holes in the same group are arranged on the same straight line.

[0022] The number of the clamps is the same as the number of groups of clamp fixing holes.

[0023] Furthermore, the fixture is equipped with a built-in temperature sensor.

[0024] Furthermore, a plurality of turntable fixing holes are arranged on the turntable and around the wire hole at intervals, and screws pass through the turntable fixing holes to fix the turntable on the turntable.

[0025] Furthermore, the heating device is a ceramic heating rod or a laser heater.

[0026] Furthermore, a heat reflecting plate is installed between the turntable base and the turntable.

[0027] Furthermore, the spraying device also includes an air compressor.

[0028] The box body is provided with a paint pressure tank air outlet, a cleaning pressure tank air outlet and an air inlet filter valve, and the paint pressure tank and the cleaning pressure tank are also installed on the box body.

[0029] The paint pressure tank is provided with an air inlet I and a material outlet I, wherein the air inlet I is connected to the air outlet of the paint pressure tank, and the material outlet I is connected to the spray gun.

[0030] The cleaning pressure tank is provided with an air inlet II and a material outlet II, the air inlet II is connected to the air outlet of the cleaning pressure tank, and the material outlet II is connected to the spray gun.

[0031] A control valve is provided at the air outlet of the paint pressure tank and the air outlet of the cleaning pressure tank, and the switch of the control valve is adjusted by a control device.

[0032] The air compressor is connected to an air intake filter valve.

[0033] The air compressor compresses the air in the box into high-pressure gas. Since the box is connected to the paint pressure tank or the cleaning pressure tank, the paint pressure tank or the cleaning pressure tank discharges the liquid in the tank into the spray gun under the action of high pressure.

[0034] Furthermore, the spraying modes of the spray gun include spot spraying and fan spraying.

[0035] Furthermore, the controller is a programmable logic controller or an embedded controller.

[0036] Furthermore, universal wheels are provided at the bottom of the box.

[0037] The technical effect of the present invention is unquestionable, and the beneficial effects of the present invention are as follows:

[0038] 1. The present invention heats and rotates the gear by means of a fixture, a heating device and a turntable, thereby ensuring that the gear reaches the temperature requirement for polymer material spraying and ensuring the stability of the coating spraying thickness.

[0039] 2. The present invention uses an electronically controlled pressure valve to accurately adjust the spray switch, airflow and paint flow to achieve a uniform spraying effect with high spraying quality.

[0040] 3. The control device of the present invention can monitor the equipment status and operating parameters in real time, significantly improving the accuracy and efficiency of gear coating processing, and has a high degree of automation. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1This is the structural diagram of the high-precision all-round polymer coating spraying system;

[0042] Figure 2 This is a schematic diagram of the overall structure of the gear preheating rotating device;

[0043] Figure 3 This is a schematic diagram of the overall front structure of the gear preheating rotating device;

[0044] Figure 4 This is a schematic diagram of the fixture installation structure;

[0045] Figure 5 It is a schematic diagram of the turntable structure;

[0046] Figure 6 Schematic diagram of the end face of the vertical section of the fixture when three fixtures are used to fix the gear in order to reduce the limit on the minimum inner diameter of the gear;

[0047] Figure 7 This is a schematic diagram of the spray gun bracket structure;

[0048] Figure 8 It is a schematic diagram of the control device structure.

[0049] In the figure: fixture 1; turntable 2; turntable 3; heating device 4; heat reflecting plate 5; turntable base 6; conductive slip ring 7; hyperbolic reducer 8; motor 9; spray gun 10; spray gun bracket 11; paint pressure tank 12; cleaning pressure tank 13; box 14; paint pressure tank outlet 1501; cleaning pressure tank outlet 1502; air intake filter valve 16; atomizing air outlet 1701; action control air outlet 1702; display screen 18; knob, button or touch button 19; reset / emergency stop button 20; bottom plate 21; mounting hole 2101; gear 22; temperature sensor mounting position 23; horizontal section 101; vertical section 102; waist-shaped hole 1011; wire hole 201; fixture fixing hole 202; turntable fixing hole 203; vertical rod 1101; adjustment rod 1102; fixing rod 1103; fixing seat 1104; heavy plate 1105. DETAILED DESCRIPTION

[0050] The present invention is further described below in conjunction with the embodiments, but it should not be understood that the above subject matter of the present invention is limited to the following embodiments. Without departing from the above technical ideas of the present invention, various substitutions and changes are made according to the common technical knowledge and customary means in the art, which should all be included in the protection scope of the present invention.

[0051] Embodiment 1:

[0052] See also Figure 1 , a high-precision all-round polymer coating spraying system for gears, including a gear preheating rotating device, a spraying device and a control device.

[0053] See also Figure 2 to Figure 6 The gear preheating rotating device includes a fixture 1, a turntable 2, a turntable 3, a heating device 4, a turntable base 6, a conductive slip ring 7, a hyperbolic reducer 8, and a motor 9 connected to the hyperbolic reducer 8.

[0054] The turntable 2 and the turntable 3 are an integrally formed structure.

[0055] The hyperbolic reducer 8 is provided with a conductive slip ring 7 and a turntable 3 .

[0056] The turntable 3 is located above the conductive slip ring 7 .

[0057] The slip ring rotor of the conductive slip ring 7 is fixedly connected to the rotating shaft of the turntable 3 , and a turntable base 6 is provided between the conductive slip ring 7 and the turntable 3 . The turntable base 6 is sleeved outside the rotating shaft for supporting the turntable 3 .

[0058] The turntable 2 is fixed on the turntable 3 and rotates together with the turntable 3 .

[0059] A wire hole 201 is provided at the center of the turntable 2, and N groups of clamp fixing holes 202 are spaced around the wire hole 201. N L-shaped clamps 1 for fixing the inner hole of the gear 22 are fixed to the clamp fixing holes 202 of the turntable 2 by bolts, so that the clamps 1 and the gear 22 clamp an inner cavity for placing the heating device 4.

[0060] The conductive wire of the conductive slip ring 7 passes through the conductive wire hole and is connected to the heating device 4 to provide power supply for the heating device 4 .

[0061] See also Figure 7 The spraying device includes a spray gun 10, a spray gun bracket 11, a paint pressure tank 12 and a cleaning pressure tank 13.

[0062] The spray gun bracket 11 is an adjustable bracket, on which the spray gun 10 is mounted, and the spraying angle of the spray gun 10 is controlled by adjusting the angle of the bracket.

[0063] The paint pressure tank 12 and the cleaning pressure tank 13 are connected to the spray gun 10 to provide paint and cleaning agent to the spray gun 10 .

[0064] See also Figure 8 The control device includes a box body 14 and a controller, a sensor, a control valve and a control panel integrated on the box body 14.

[0065] The heating temperature of the heating device 4 , the rotation speed and the rotation direction of the turntable 3 and the spraying pressure of the spray gun 10 can be adjusted by the control device.

[0066] Embodiment 2:

[0067] The main structure of this embodiment is the same as that of embodiment 1. Figure 2 to Figure 5 The clamp 1 is an integrally formed structure, including a horizontal section 101 and a vertical section 102 .

[0068] The horizontal section 101 is provided with a waist-shaped hole 1011 with scale markings, and the waist-shaped hole 1011 cooperates with the fixture fixing hole 202. By adjusting the position of the fixture 1 on a certain column of fixture fixing holes 202, gears of different sizes can be adapted and the gears can be ensured to be installed in the center of the turntable 2.

[0069] See also Figure 6 The vertical section 102 is a columnar structure. When the gear is fixed on the fixture 1, one side is used to clamp the inner hole of the gear, which is recorded as end face A, and the other sides are located in the inner hole of the gear. The two sides adjacent to the end face A are recorded as end face B and end face C, and the end face B / end face C is connected to the end face A through an arc surface.

[0070] Embodiment 3:

[0071] The main structure of this embodiment is the same as any one of Embodiments 1 to 2. Figure 5 The turntable 2 is provided with three groups of fixture fixing holes 202, and the center lines of each group of fixture fixing holes 202 are arranged at intervals of 120°.

[0072] Each group of fixture fixing holes includes a plurality of fixture fixing holes 202 , and the fixture fixing holes 202 in the same group are arranged on the same straight line (center line).

[0073] The number of the clamps 1 is the same as the number of groups of the clamp fixing holes 202 .

[0074] The clamp 1 is an integrally formed structure, including a horizontal section 101 and a vertical section 102 .

[0075] When three clamps 1 are used to fix the gear, in order to reduce the limit on the minimum inner diameter of the gear, one end of the vertical section 102 close to the center of the gear is a prismatic structure.

[0076] See also Figure 6 When the gear is fixed on the fixture 1, one side of the vertical section 102 is used to clamp the inner hole of the gear, which is recorded as end face A. The two sides adjacent to end face A are recorded as end face B and end face C. End face B / end face C are connected to end face A through an arc surface; the side opposite to end face A is recorded as end face D, and the two sides connected to end face D are recorded as end face E and end face F. Among them, end face E and end face B are adjacent faces, end face F and end face C are adjacent faces, and the angle between end face E and end face F is 120°, and the internal angle between end face E / end face F and end face D is 150°, so that the three fixtures can be completely close to reduce the limit of the minimum inner diameter of the gear.

[0077] Embodiment 4:

[0078] The main structure of this embodiment is the same as any one of Embodiments 1 to 3. Furthermore, the fixture 1 is equipped with a temperature sensor for real-time monitoring of the gear temperature and feeding the data back to the control device so as to adjust the power of the heating device and ensure accurate control of the heating process.

[0079] In this embodiment, the temperature sensor installation position 23 is shown in FIG. Figure 4 .

[0080] Embodiment 5:

[0081] The main structure of this embodiment is the same as any one of Embodiments 1 to 4. Figure 5 A plurality of turntable fixing holes 203 are provided on the turntable 2 and around the wire hole 201 at intervals, and screws pass through the turntable fixing holes 203 to fix the turntable 2 on the turntable 3.

[0082] Embodiment 6:

[0083] The main structure of this embodiment is the same as any one of Embodiments 1 to 5. Furthermore, the heating device 4 is a ceramic heating rod or a laser heater.

[0084] Embodiment 7:

[0085] The main structure of this embodiment is the same as any one of Embodiments 1 to 6. Figure 2 or Figure 3 A heat reflecting plate 5 is installed between the turntable base 6 and the turntable 3.

[0086] The heat reflecting plate 5 can reflect the heat transmitted downward after the turntable 2 absorbs the heat emitted by the heating device 4, effectively reducing the heat loss and reducing the heat absorbed by the hyperbolic reducer 8 and the motor 9 below the turntable 2.

[0087] In this embodiment, a 304 stainless steel mirror reflector is used.

[0088] Embodiment 8:

[0089] The main structure of this embodiment is the same as any one of Embodiments 1 to 7. Figure 2 or Figure 3 The gear preheating rotating device also includes a base plate 21, and a mounting hole 2101 is reserved on the base plate 21 to fix the hyperbolic reducer 7 and the motor 8, thereby reducing the vibration and displacement of the equipment during operation and improving the stability and accuracy of the overall system.

[0090] In addition, the mounting holes 2101 on the base plate 21 facilitate the fixing and disassembly of the equipment, and are beneficial to the maintenance and replacement of the equipment, especially when the motor or reducer needs to be repaired.

[0091] Embodiment 9:

[0092] The main structure of this embodiment is the same as any one of Embodiments 1 to 8. Figure 7 The spray gun bracket 11 includes a vertical rod 1101, an adjusting rod 1102, a fixing rod 1103, a fixing seat 1104 and a heavy plate 1105.

[0093] The vertical rod 1101 is fixed on the plate surface of the heavy plate 1105 , and a fixing seat 1104 is installed on the rod body of the vertical rod 1101 . The spraying height of the automatic spray gun 10 can be adjusted by adjusting the position of the fixing seat 1104 on the vertical rod 1101 .

[0094] The fixing seat 1104 is provided with two through holes with axes perpendicular to each other, one of which is used to connect the vertical rod 1101 and is marked as through hole I, and the other is used to connect the adjusting rod 1102 and is marked as through hole II.

[0095] The vertical rod 1101 passes through the through hole I and is fixed by radial screws.

[0096] The fixing rod 1103 includes a fixing rod I and a fixing rod II.

[0097] One end of the fixing rod I extends into the through hole II, and is then mounted on the fixing seat 1104 by radial screws.

[0098] The fixing rod I is provided with a through hole III, the adjusting rod 1102 passes through the through hole III, and the adjusting rod 1102 is fixed to the fixing rod I by a radial screw.

[0099] A fixing rod II is installed on the end of one end of the adjusting rod 1102, and the automatic spray gun 10 is connected through the fixing rod II. One end of the fixing rod II extends into the fixing hole of the spray gun and is fixed by a radial screw fixing method.

[0100] Embodiment 10:

[0101] The main structure of this embodiment is the same as any one of embodiments 1 to 8. Furthermore, the spray gun holder 11 adopts a mechanical arm, and the spray gun 10 is set on the mechanical arm. The motion trajectory and speed of the mechanical arm are controlled by programming to achieve accurate and flexible spraying operations. Meet complex spraying requirements. Users can easily replace the spray gun, or adjust its angle and position according to the complexity of the actual spraying task and the shape of the gear to achieve accurate and uniform coating application.

[0102] Embodiment 11:

[0103] The main structure of this embodiment is the same as any one of Embodiments 1 to 10. Furthermore, the spraying modes of the spray gun 10 include spot spraying and fan-shaped spraying.

[0104] Embodiment 12:

[0105] The main structure of this embodiment is the same as any one of Embodiments 1 to 11. Furthermore, the spraying device also includes an air compressor.

[0106] The housing 14 is provided with a paint pressure tank air outlet 1501 , a cleaning pressure tank air outlet 1502 and an air inlet filter valve 16 , and the housing 14 is also provided with a paint pressure tank 12 and a cleaning pressure tank 13 .

[0107] The paint pressure tank 12 is provided with an air inlet I and a discharge port I, wherein the air inlet I is connected to the paint pressure tank air outlet 1501, and the discharge port I is connected to the spray gun 10.

[0108] The cleaning pressure tank 13 is provided with an air inlet II and a material outlet II. The air inlet II is connected to the cleaning pressure tank air outlet 1502 , and the material outlet II is connected to the spray gun 10 .

[0109] The paint pressure tank air outlet 1501 and the cleaning pressure tank air outlet 1502 are both provided with control valves, and the switches of the control valves are adjusted by a control device.

[0110] The air compressor is connected to the air intake filter valve 16 .

[0111] The air compressor compresses the air in the box 14 into high-pressure gas. Since the box 14 is connected to the paint pressure tank 12 or the cleaning pressure tank 13, the paint pressure tank 12 or the cleaning pressure tank 13 discharges the liquid in the tank into the spray gun 10 under high pressure.

[0112] Embodiment 13:

[0113] The main structure of this embodiment is the same as any one of Embodiments 1 to 12. Furthermore, the paint pressure tank 12 and the cleaning pressure tank 13 are provided with a pressure relief port, and the pressure relief port is connected to a pressure relief device to release gas pressure before opening the paint pressure tank 12 or the cleaning pressure tank 13.

[0114] Embodiment 14:

[0115] The main structure of this embodiment is the same as any one of Embodiments 1 to 13. Furthermore, the box body 14 is provided with an atomizing air outlet 1701 and an action control air outlet 1702.

[0116] The atomizing air outlet 1701 and the action control air outlet 1702 are both provided with control valves, and the switches of the control valves are adjusted by a control device.

[0117] The spray gun 10 is respectively connected to the atomizing air outlet 1701, the action control air outlet 1702, the discharge port I on the paint pressure tank 12 and the discharge port II on the cleaning pressure tank 13 through pipelines.

[0118] After the paint in the paint pressure tank 12 and the cleaning agent in the cleaning pressure tank 13 are delivered to the spray gun 10 , they need to be atomized inside the spray gun 10 and then sprayed out from the nozzle of the spray gun 10 .

[0119] The box 14 provides gas capable of atomizing paint or cleaning agent to the spray gun 10 through the atomizing air outlet 1701, and supplies air to the spray gun 10 through the action control air outlet 1702. The spray gun 10 is opened and closed by compressing the supplied air.

[0120] Basic principle of spray gun switch:

[0121] The spray gun is equipped with a pneumatic piston mechanism, which consists of a stainless steel needle, a piston and a high-pressure spring. When compressed air is supplied, the pressure of the compressed air pushes the piston open, creating a gap between the stainless steel needle and the nozzle, allowing the liquid to be sprayed out. At the same time, the sprayed liquid comes into contact with the atomizing air to produce an atomizing effect. When the compressed air stops supplying, the high-pressure spring pushes the piston and the stainless steel needle forward, making them fit tightly with the nozzle, preventing the liquid from passing through with high precision, thereby closing the spray gun.

[0122] The air in the box 14 and the gas of the atomized paint cleaning agent are both from an air compressor. The air compressor is connected to the air inlet filter valve on the box to provide gas for the box.

[0123] Embodiment 15:

[0124] The main structure of this embodiment is the same as any one of Embodiments 1 to 14. Furthermore, the box body 14 is provided with a paint pressure tank outlet 1501, a cleaning pressure tank outlet 1502, an atomizing air outlet 1701 and an action control air outlet 1702.

[0125] Each air outlet is provided with a control valve, by means of which the air flow and the paint flow can be precisely regulated.

[0126] The control valve is controlled by a control device.

[0127] Embodiment 16:

[0128] The main structure of this embodiment is the same as any one of Embodiments 1 to 15. Furthermore, the control valve is an electronically controlled pressure valve.

[0129] In some cases where the precision requirement is not high, the "electronically controlled pressure valve" can be replaced with a "mechanically controlled pressure valve". The mechanically controlled pressure valve has a simple structure, is easy to maintain, and does not require power support.

[0130] Embodiment 17:

[0131] The main structure of this embodiment is the same as any one of Embodiments 1 to 16. Furthermore, the sensors of the control device include a speed sensor, a temperature sensor, and a paint flow sensor, which are used to monitor the equipment status in real time to ensure the accuracy of various operations.

[0132] The temperature sensor is arranged inside the fixture 1 to monitor the gear temperature in real time and send the data back to the temperature control system of the control device so as to adjust the power of the heating device and ensure the precise control of the heating process.

[0133] The speed sensor is arranged in the hyperbolic reducer 8 .

[0134] The paint flow sensor is arranged in front of the air outlet of the paint pressure tank and measures the paint flow by measuring the air flow at the air outlet.

[0135] Embodiment 18:

[0136] The main structure of this embodiment is the same as any one of Embodiments 1 to 17. Furthermore, the controller is a programmable logic controller or an embedded controller, which has powerful data processing capabilities and real-time control functions, and supports complex control logic, including multi-device synchronous control and abnormality detection functions, to ensure stable operation of the system.

[0137] Embodiment 19:

[0138] The main structure of this embodiment is the same as any one of Embodiments 1 to 18. Figure 8 The control panel includes a display screen 18 , a plurality of knobs, buttons or touch keys 19 and a reset / emergency stop button 20 .

[0139] The display screen 18 shows the equipment status, parameter settings and real-time data. The heating temperature, turntable speed, turntable rotation direction and spraying pressure values ​​can be adjusted through the knob, button or touch key 19. The reset / emergency stop button 20 ensures that all operations can be terminated quickly and conveniently in an emergency.

[0140] Embodiment 20:

[0141] The main structure of this embodiment is the same as that of Embodiment 19. Furthermore, the equipment status includes a standby status and a spraying status.

[0142] The parameter settings include atomizing air pressure, motion control air pressure, paint pressure tank pressure, cleaning pressure tank pressure, paint flow rate, nozzle size, spray angle, spray width, spray distance, turntable rotation speed, turntable rotation direction and heating temperature.

[0143] The real-time data includes turntable rotation speed, turntable rotation direction, gear temperature, and paint flow rate.

[0144] Embodiment 21:

[0145] The main structure of this embodiment is the same as any one of Embodiments 1 to 20. Figure 8 The bottom of the box 14 is provided with universal wheels to facilitate the movement of the control device.

[0146] Embodiment 22:

[0147] The main structure of this embodiment is the same as any one of Embodiments 1 to 21. Furthermore, the high-precision all-round polymer coating spraying system is provided with safety devices such as overheat protection, leakage protection, and emergency stop button to ensure the safety of the operator.

[0148] Safety covers are designed to protect operators from direct contact with hot components and spray areas.

[0149] Embodiment 23:

[0150] The main structure of this embodiment is the same as any one of Embodiments 1 to 22. Furthermore, a high-efficiency ventilation system is configured in the spraying area and equipped with a filtering device to control harmful gases and dust and improve the working environment.

[0151] Embodiment 24:

[0152] The main structure of this embodiment is the same as any one of Embodiments 1 to 23. Furthermore, the spray gun is detachable: the spray gun is designed as a detachable module, which can be easily installed on a robotic arm or a bracket, so that the spray gun can flexibly adapt to different spraying requirements.

[0153] When a robotic arm is used, the motion trajectory and speed of the robotic arm can be controlled by programming to achieve precise and flexible spraying operations. It can meet complex spraying requirements. Users can easily replace the spray gun, or adjust its angle and position according to the complexity of the actual spraying task and the shape of the gear to achieve precise and uniform coating application.

[0154] Modular design: The spray system is designed with interchangeable modular components, including spray guns, heating systems and fixtures. According to different spraying tasks and gear specifications, modules can be quickly replaced and adjusted to improve the flexibility and adaptability of the system.

[0155] Embodiment 25:

[0156] The main structure of this embodiment is the same as any one of Embodiments 1 to 24. Furthermore, a high-precision all-round polymer coating spraying system for gears includes a gear preheating rotation device, a spraying device, and a control device.

[0157] 1. Gear preheating rotation device

[0158] 1.1 Function: Drive the gear to rotate steadily and heat it to the predetermined spraying temperature to ensure that the gear surface is evenly heated to meet the requirements of coating spraying.

[0159] 1.2 Composition:

[0160] (1) Clamp: The clamp is a three-jaw design made of high-strength alloy material. The clamp fixes the gear by fixing the inner diameter of the gear.

[0161] ① The end of the fixture is designed with a fixed adjustment mechanism to adapt to gears with different inner diameters. The fixed adjustment hole is marked with scales. The gear is ensured to be installed in the center of the disc by setting the bolt fixing positions on the three fixtures to be the same.

[0162] ② The angles on both sides of the front section of the fixture are 120°, and the three fixtures can be completely close together, reducing the minimum inner diameter limit of the gear, and the front tip of the fixture is flattened to ensure that the heating rod wire can enter the heating rod wire hole when the fixture is completely close together.

[0163] ③The fixture is equipped with a high-precision temperature sensor to monitor the gear temperature in real time, and send the data back to the temperature control system to adjust the power of the heating rod to ensure accurate control of the heating process.

[0164] (2) Heating rod: The heating rod is embedded in the fixture and a high-efficiency ceramic heating rod is selected to ensure uniform heating of the gear surface and control the heating temperature.

[0165] (3) Turntable: Made of high-temperature resistant alloy material, it can withstand high temperature environment without deformation. There are multiple fixture fixing holes on the turntable to facilitate the installation and adjustment of fixtures to adapt to gears with different inner diameters.

[0166] (4) 304 mirror heat reflection plate: A 304 mirror heat reflection plate is installed under the turntable to reflect the heat transmitted downward after the turntable absorbs the heating rod, effectively reducing heat loss and reducing the heat absorbed by the reducer and motor under the turntable.

[0167] (5) Conductive slip ring: The conductive slip ring is installed on the rotating axis of the turntable to realize the power supply of the heating rod. The fixed part of the slip ring is installed on the fixed bracket of the reducer, and the rotating part is connected to the rotating shaft of the turntable to ensure stable power transmission during the rotation of the turntable.

[0168] (6) Motor and hyperbolic reducer: The motor drives the turntable to rotate through the reducer. A digital stepper motor and a high-precision hyperbolic reducer are used to achieve precise control of the rotation speed and direction, ensuring the stability and speed adjustability of the turntable at high temperatures.

[0169] (7) Bottom plate: The hyperboloid reducer and motor are mounted on the bottom plate, and mounting holes are left on the bottom plate to fix the gear preheating rotating device. The bottom plate provides solid support for the reducer and motor, reduces the vibration and displacement of the equipment during operation, and improves the stability and accuracy of the overall system. The mounting holes allow the equipment to be fixed and disassembled, which facilitates the maintenance and replacement of the equipment, especially when the motor or reducer needs to be repaired.

[0170] 2. Spraying device

[0171] 2.1 Function: Automatically spray polymer coating evenly onto the heated gear surface to form a uniform coating.

[0172] 2.2 Composition:

[0173] (1) Air compressor: The air compressor is responsible for providing stable air pressure to all parts of the spray gun device.

[0174] (2) Automatic spray gun: The spray gun is installed on an adjustable bracket and is designed as a multi-functional spray gun. It is equipped with a high-precision nozzle and supports multiple modes such as spot spraying and fan-shaped spraying. The nozzle is designed to be easy to disassemble and clean to meet different coating requirements.

[0175] (3) Spray gun bracket: The bracket has a stable structure, increases the area and weight of the heavy plate, improves stability, and has a precise angle adjustment mechanism to adapt to different spraying angle requirements.

[0176] (4) Spray gun adjustment system: The electronically controlled pressure valve is used to accurately control the switch, airflow and paint flow of the spray gun to ensure the accuracy and stability of the spraying process.

[0177] (5) Paint pressure tank: Provides a stable supply of paint. Made of high-pressure and corrosion-resistant materials, the paint pressure tank is equipped with an automatic replenishment, flow monitoring and alarm system to ensure stable paint flow and timely replenishment to avoid interruptions during the spraying process. The built-in stirring system prevents paint sedimentation and ensures the uniformity and consistency of the paint.

[0178] (6) Cleaning the pressure tank: After spraying is completed, start the cleaning program to absorb the cleaning agent in the cleaning pressure tank, remove the residual paint in the pipeline and the paint on the turntable, keep the spray gun, pipeline and turntable clean, and reduce manual maintenance and downtime.

[0179] 3. Control device

[0180] 3.1 Function: Realize unified control of multiple operations such as turntable rotation, gear heating, spray gun spraying, etc. to ensure synchronization and coordination of various operations.

[0181] 3.2 Composition:

[0182] (1) Controller: Use industrial-grade PLC or embedded control system with powerful data processing capabilities and real-time control functions, support complex control logic, including multi-device synchronous control and anomaly detection functions, to ensure stable system operation.

[0183] (2) Sensors: including speed sensors, temperature sensors, and paint flow sensors, which monitor equipment status in real time to ensure the accuracy of each operation.

[0184] (3) Control panel: The display interface of the control panel is a liquid crystal display (LCD or touch screen, which displays the status of various parts of the equipment, parameter settings and real-time data. The control panel has knobs, buttons or touch keys for adjusting the values ​​of heating temperature, turntable speed, turntable rotation direction, spraying pressure, etc. The control panel is equipped with a reset / emergency stop button to ensure that all operations can be terminated quickly and conveniently in an emergency.

[0185] Embodiment 26:

[0186] The main structure of this embodiment is the same as any one of Embodiments 1 to 25, and further,

[0187] 1. Consider using more efficient laser heaters, combined with intelligent temperature control systems, to achieve faster heating rates and more uniform temperature distribution. Speed ​​up the preheating process, improve heating uniformity, and reduce the impact of temperature fluctuations on spray quality.

[0188] 2. Provide more visual data, such as real-time display of gear temperature distribution map, coating thickness map, etc., to help operators better understand and control the spraying process. The operation interface is more intuitive, users can react faster and make necessary adjustments, reducing the risk of misoperation.

[0189] 3. Introduce more efficient servo motors to replace stepper motors to obtain higher speed control accuracy and stability. Servo motors can provide more precise speed and torque control, thereby improving the accuracy of spraying. Improve the system response speed and the rotation accuracy of the turntable, ensure that the turntable can still maintain stability at different temperatures, and reduce vibration and errors in the operation of the turntable.

[0190] 4. Replace the paint pressure tank with a diaphragm paint spray pump. The diaphragm paint spray pump can provide more stable pressure and flow, reduce paint waste, and better control the uniformity and consistency of the paint.

[0191] 5. Intelligent heating and temperature control system: The intelligent heating and temperature control system has an adaptive heating function, which can automatically adjust the heating power according to the gear material and the preset temperature curve to ensure heating uniformity. The machine learning algorithm is used to analyze the heating characteristics and spraying requirements of different gear materials, and optimize the heating time and temperature distribution. The system automatically adjusts the heating power according to the heating history data and real-time feedback to improve heating uniformity and energy saving. Before spraying begins, the intelligent temperature control system can analyze the heating status of the gear in real time, and automatically adjust the heating power according to the preset heating curve to ensure that the surface temperature of the gear is uniform and meets the spraying requirements.

[0192] 6. Touch screen interface: Provides a user-friendly operation panel that displays device status and operation options in real time for easy user operation.

Claims

1. A high-precision all-round polymer coating spraying system for gears, characterized by: It includes a gear preheating rotating device, a spraying device and a control device; The gear preheating rotating device comprises a fixture (1), a turntable (2), a turntable (3), a heating device (4), a turntable base (6), a conductive slip ring (7), a hyperbolic reducer (8), and a motor (9) connected to the hyperbolic reducer (8); The hyperbolic reducer (8) is provided with a conductive slip ring (7) and a turntable (3); The turntable (3) is located above the conductive slip ring (7); The slip ring rotor of the conductive slip ring (7) is fixedly connected to the rotating shaft of the turntable (3), and a turntable base (6) is provided between the conductive slip ring (7) and the turntable (3), and the turntable base (6) is sleeved outside the rotating shaft and is used to support the turntable (3); The turntable (2) is fixed on the turntable (3) and rotates together with the turntable (3); A wire hole (201) is provided at the center of the turntable (2), and N groups of fixture fixing holes (202) are spaced around the wire hole (201); N L-shaped fixtures (1) for fixing the inner hole of the gear (22) are fixed to the fixture fixing holes (202) of the turntable (2) by bolts, so that the fixture (1) and the gear (22) form an inner cavity for placing the heating device (4); The conductive wire of the conductive slip ring (7) passes through the conductive wire hole and is connected to the heating device (4), thereby providing power supply to the heating device (4); The spraying device comprises a spray gun (10), a spray gun support (11), a paint pressure tank (12) and a cleaning pressure tank (13); The spray gun bracket (11) is an adjustable bracket, on which the spray gun (10) is mounted, and the spraying angle of the spray gun (10) is controlled by adjusting the angle of the bracket; The coating pressure tank (12) and the cleaning pressure tank (13) are connected to the spray gun (10) to provide coating and cleaning agent to the spray gun (10); The control device comprises a box (14) and a controller, a sensor, a control valve and a control panel integrated on the box (14); The heating temperature of the heating device (4), the rotation speed and the rotation direction of the turntable (3) and the spraying pressure of the spray gun (10) can be adjusted by the control device.

2. A high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The rotating disk (2) is provided with three groups of clamp fixing holes (202), and each group of clamp fixing holes (202) is arranged at intervals of 120°; Each group of clamp fixing holes includes a plurality of clamp fixing holes (202), and the clamp fixing holes (202) in the same group are arranged on the same straight line; The number of the clamps (1) is the same as the number of groups of clamp fixing holes (202).

3. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The clamp (1) has a built-in temperature sensor.

4. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: A plurality of turntable fixing holes (203) are arranged on the turntable (2) at intervals around the wire hole (201), and screws pass through the turntable fixing holes (203) to fix the turntable (2) on the turntable (3).

5. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The heating device (4) is a ceramic heating rod or a laser heater.

6. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: A heat reflection plate (5) is installed between the turntable base (6) and the turntable (3).

7. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The spraying device also includes an air compressor; The housing (14) is provided with a paint pressure tank air outlet (1501), a cleaning pressure tank air outlet (1502) and an air inlet filter valve (16), and the housing (14) is also provided with a paint pressure tank (12) and a cleaning pressure tank (13); The paint pressure tank (12) is provided with an air inlet I and a material outlet I, the air inlet I is connected to the paint pressure tank air outlet (1501), and the material outlet I is connected to the spray gun (10); The cleaning pressure tank (13) is provided with an air inlet II and a material outlet II, wherein the air inlet II is connected to the cleaning tank air outlet (1502), and the material outlet II is connected to the spray gun (10); The paint pressure tank air outlet (1501) and the cleaning pressure tank air outlet (1502) are both provided with control valves, and the switch of the control valves is adjusted by a control device. The air compressor is connected to an air intake filter valve (16); The air compressor compresses the air in the box (14) into high-pressure gas. Since the box (14) is connected to the paint pressure tank (12) or the cleaning pressure tank (13), the paint pressure tank (12) or the cleaning pressure tank (13) discharges the liquid in the tank into the spray gun (10) under the action of high pressure.

8. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The spraying modes of the spray gun (11) include spot spraying and fan-shaped spraying.

9. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The controller is a programmable logic controller or an embedded controller.

10. The high-precision all-round polymer coating spraying system for gears according to claim 1, characterized in that: The bottom of the box body (14) is provided with universal wheels.

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