Small workpiece coating insulating material and coating method

Abstract

The invention discloses a small workpiece coating insulating material and a coating method, and belongs to the technical field of workpiece surface treatment for high-voltage electrical equipment manufacturing, and the method comprises the following steps: performing high-speed stirring and ultrasonic dispersion mixing on a rubber matrix, a solvent and an additive to obtain an insulating coating, and performing vacuum defoaming; the rubber matrix is made of high-temperature-resistant silicon rubber; the solvent is xylene; the additive comprises a cross-linking agent and a flame retardant; coating equipment is filled with the insulating paint, in the coating process, the coating thickness, the coating speed, the coating flow and the coating pressure are monitored and adjusted in real time, the insulating paint is conveyed to a coating pen through a diaphragm pump, and the coating pen moves relative to the surface of the pretreated workpiece to evenly stricken the insulating paint; and carrying out post-treatment to obtain the small-sized workpiece coating insulating material. Full-process automatic monitoring is achieved, sensors are combined with visual inspection, manual intervention is reduced, and the production efficiency is improved; the problems of uneven coating and unstable insulation are solved, and the requirements of high-voltage electric small workpieces are met.

Description

Technical Field

[0001] This invention belongs to the field of workpiece surface treatment technology in the manufacture of high-voltage electrical equipment, and specifically relates to a method for coating small workpieces with insulating materials. Background Technology

[0002] In the high-voltage electrical industry, the insulation coating of small workpieces is a crucial step in ensuring the electrical performance and operational safety of equipment. Insulating coatings, as commonly used insulating materials, directly affect the safety and reliability of high-voltage electrical equipment. Currently, the traditional insulation coating process for small workpieces mainly involves manually winding insulating cloth and then dripping high-temperature curing epoxy adhesive onto its outer surface. This process suffers from problems such as complexity, long production cycles, and low product qualification rates. Furthermore, because epoxy adhesive is liquid with a low molecular weight, it is prone to molecular chain breakage during high-temperature curing, and volatile organic compound emissions are generated. In the high-voltage electrical industry, the insulation coating of small workpieces presents the following problems: uneven coating thickness leads to unstable insulation performance, making it difficult to meet the stringent requirements for high reliability and stability of the insulating coating under high-voltage environments. The lack of effective coordination between workpiece transportation, positioning, and the coating process results in low coating efficiency, frequent manual intervention, and an inability to meet the demands of large-scale, high-quality production in the high-voltage electrical industry. The lack of precise control in post-processing steps such as drying easily leads to coating defects, affecting the overall insulation performance and service life of the equipment. The main reasons for these problems include: the traditional coating process lacks precise parameter control and real-time monitoring and adjustment mechanisms. Insufficient pretreatment of the workpiece affects the adhesion between the insulating material and the workpiece. The insulating coating formulation is not optimized enough to meet the special requirements of high-voltage electrical equipment. The coating process has a low degree of automation, and manual operation easily introduces errors. The post-processing is not refined enough, failing to guarantee the uniformity and density of the coating.

[0003] In existing insulation coating processes, the lack of effective coordination between workpiece conveying, positioning, and coating processes leads to low coating efficiency and frequent manual intervention. High-voltage electrical equipment has extremely high requirements for the curing effect and coating density of insulating materials, but traditional processes lack precise control in post-processing stages such as drying, easily causing coating defects and affecting the overall insulation performance and service life of the equipment. Especially under high-voltage environments, the reliability and stability of the coating become urgent problems to be solved, which are directly related to the safe operation of the equipment. Regarding the solution to the problems of uneven coating thickness, unstable insulation performance, and low coating efficiency in the coating process of small workpieces in the high-voltage electrical industry, Chinese patent application CN117619703A discloses an insulating coating coating method, which includes steps such as pre-coating preparation, workpiece surface treatment, stirring of the insulating coating, and applying the insulating coating to the workpiece for curing and drying. This method improves adhesion by adding an abrasive paste to the insulating coating and then grinding the workpiece to a certain roughness, which helps to improve the fit between the workpiece and the insulating coating. However, this method still has shortcomings in the control of curing and drying conditions, which can easily affect the quality stability of the coating. Chinese patent application CN116943994A discloses a construction process for a high-temperature and high-voltage resistant insulating coating. The process includes pretreatment of the workpiece, determining spraying and polishing parameters using a coating quality control model, placing the pretreated workpiece in an electrostatic field for spraying, and finally drying and polishing. This process uses a coating quality control model to determine the polishing and spraying parameters, and then performs the processing based on these determined parameters. However, this process still has shortcomings in terms of improving the pretreatment process, making it difficult to effectively improve the adhesion and durability of the dry coating film.

[0004] Therefore, developing a process for efficiently and uniformly coating insulating materials on small workpieces, significantly improving coating quality and stability, while simultaneously increasing the automation level of the coating process, reducing labor costs, and enhancing production efficiency, is a pressing technical challenge for the high-voltage electrical industry. This will not only meet the stringent insulation performance requirements of high-voltage electrical equipment but also drive the high-voltage electrical industry towards large-scale, high-quality production. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, the present invention aims to provide a coating method for insulating materials on small workpieces, so as to solve the technical problems of uneven coating thickness, low coating efficiency and inaccurate post-processing control in the insulation coating process of small workpieces in the high voltage electrical industry, which leads to unstable insulation performance and low production efficiency.

[0006] To achieve the above objectives, the present invention employs the following technical solution: This invention discloses a method for coating insulating materials onto small workpieces, comprising: 1) An insulating coating is obtained by mixing a rubber matrix, solvent, and additives through high-speed stirring and ultrasonic dispersion, followed by vacuum degassing; the rubber matrix is ​​high-temperature resistant silicone rubber; the solvent is xylene; and the additives include crosslinking agents and flame retardants. 2) Load the insulating coating into the coating equipment. During the coating process, monitor and adjust the coating thickness, speed, coating flow rate and pressure in real time. The insulating coating is delivered to the coating pen through a diaphragm pump. The coating pen moves relative to the pre-treated workpiece surface to evenly scrape the insulating coating. After post-processing, small workpieces are coated with insulating material.

[0007] Preferably, in step 1), the mass ratio of the rubber matrix, solvent and additive is (70-75):(20-25):(5-10).

[0008] Preferably, in step 1), the conditions for high-speed stirring include: stirring at a speed of 1000-1500 rpm for 5 minutes; The conditions for ultrasonic dispersion include: turning on an ultrasonic disperser with a power of 200-300W and dispersing at a frequency of 40-50kHz for 15 minutes.

[0009] Preferably, in step 2), the pretreatment conditions for the workpiece include: sequentially performing ultrasonic cleaning and activation and anodizing treatment on the workpiece to form a microporous oxide film, and then cleaning and drying; the ultrasonic treatment frequency is 30-40kHz and the time is 3-4 minutes; and anodizing is performed for 15-20 minutes under a DC voltage of 10-15V.

[0010] Preferably, in step 2), the coating conditions include: a coating thickness of 50-100 μm, a coating speed of 0.5-1.5 m / min, a coating flow rate of 50-100 mL / min, and a pressure of 0.1-0.3 MPa.

[0011] Preferably, in step 2), during the coating process, the pressure sensor monitors the coating pressure in real time. When the pressure deviation is large, the control system automatically adjusts the pump output pressure. The flow sensor monitors the coating flow rate in real time. When the flow rate deviation is large, the control system automatically adjusts the pump speed. The vision inspection system periodically takes pictures of the coated workpiece for inspection. If uneven coating thickness or missed coating is detected, an alarm signal is immediately issued and fed back to the control system. The control system stops the equipment operation and records the defect location. The defect is then manually handled or the equipment automatically adjusts the coating parameters for recoating.

[0012] More preferably, in step 2), the pressure deviation is automatically adjusted when it is greater than ±0.01 MPa or the flow rate deviation is greater than ±5 mL / min.

[0013] Preferably, in step 2), the coating environment temperature is controlled at 20-25℃ and the relative humidity is 40%-50%, and the test is performed every 30 minutes.

[0014] Preferably, in step 2), the post-processing includes: transferring the workpiece to the leveling station by a robot for leveling, drying with hot air and curing with hot air circulation, and finally performing visual inspection of the coating; the temperature of the hot air drying is 120-150℃, and the time is 1-3 hours; the temperature of the hot air circulation is 80-100℃, and the circulation is 3-5 times.

[0015] The present invention also discloses the insulating material for coating small workpieces used in the above-mentioned method of coating insulating material for small workpieces, comprising: 70-75 parts of rubber matrix, 20-25 parts of solvent, and 5-10 parts of additives.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention discloses a method for coating insulating materials onto small workpieces. A precisely formulated insulating coating improves coating performance. The insulating coating formula is precisely formulated according to the operating environment and insulation requirements of high-voltage electrical equipment. A combination of high-speed stirring and ultrasonic dispersion ensures uniform coating mixing, improving the coating's insulation and corona resistance. Precise control of the coating operation achieves uniform coating; by setting coating parameters, using a diaphragm pump for stable coating supply, and employing a scraping method, precise control of the coating process is achieved, ensuring uniform coating thickness. Optimized post-processing improves coating quality; a combination of leveling and hot air drying ensures coating uniformity and density, improving insulation performance and service life. A real-time monitoring and adjustment system improves production efficiency and quality; pressure sensors, flow sensors, and a vision inspection system monitor the coating process in real time, adjusting parameters or issuing alarms promptly, reducing manual intervention and improving production efficiency and product qualification rate. This method solves problems such as uneven coating thickness, unstable insulation performance, low coating efficiency, and inaccurate post-processing, meeting the stringent requirements of the high-voltage electrical industry for insulating coating of small workpieces.

[0017] Furthermore, the insulating coating is prepared using a combination of high-speed stirring and ultrasonic dispersion to ensure uniform mixing. This combination improves mixing uniformity: high-speed stirring quickly disperses large particles, while ultrasonic dispersion further breaks down small agglomerates; the combination ensures a uniform distribution of coating components at the microscale. It also improves coating stability: uniformly dispersed coating components are less prone to sedimentation or separation, improving storage stability and service life. Finally, it optimizes coating performance: a uniform coating helps form a structurally homogeneous and consistent insulating coating, improving its insulation and corona resistance. Thorough dispersion reduces agglomerates and bubbles in the coating, minimizing potential defects. Compared to single stirring or dispersion methods, this combination achieves the desired dispersion effect more quickly and efficiently, shortening coating preparation time. This ensures high-quality insulating coatings, laying the foundation for subsequent coating processes and contributing to the achievement of high-performance, high-reliability insulating coatings.

[0018] Furthermore, workpiece pretreatment improves the adhesion between the insulating material and the workpiece; ultrasonic treatment removes surface oil, impurities, and oxide layers while introducing active groups; anodizing forms a microporous oxide film. These two steps collectively enhance the adhesion between the insulating material and the workpiece, improving coating reliability and stability. The workpiece pretreatment uses ultrasonic technology to clean and activate the workpiece surface, removing oil, impurities, and oxide layers while introducing active groups. Ultrasonic treatment not only effectively cleans the workpiece surface but also introduces active groups. This dual effect significantly enhances the adhesion between the insulating material and the workpiece. By removing surface oil, impurities, and oxide layers, a clean substrate is provided for subsequent coating, reducing interface defects between the coating and the workpiece. Simultaneously, the introduced active groups can form chemical bonds with the insulating material, further improving the coating's strength and durability. Compared to traditional mechanical or chemical cleaning methods, this pretreatment method cleans the surface more thoroughly and improves surface properties at the microscopic level, thus laying the foundation for a high-quality insulating coating.

[0019] Furthermore, anodizing is performed during workpiece pretreatment to form a microporous oxide film on the metal workpiece surface. The microporous oxide film formed by anodizing offers multiple technological benefits: improved insulation performance: the oxide film itself possesses a certain degree of insulation, providing initial insulation protection for the workpiece. Enhanced coating adhesion: the microporous structure significantly increases the surface area, providing more mechanical bonding points for the insulating coating and greatly improving coating adhesion. Improved coating uniformity: the microporous structure facilitates the uniform distribution and penetration of the insulating coating, reducing localized unevenness in coating thickness. Improved corrosion resistance: the oxide film enhances the corrosion resistance of the workpiece surface, extending the service life of the equipment. Optimized surface morphology: the microporous structure reduces surface roughness, which is beneficial for the smoothness of subsequent coatings. These contributions work together to significantly improve the overall performance and reliability of the insulating coating, making it particularly suitable for the stringent requirements of high-voltage electrical equipment.

[0020] Furthermore, the coating operation employs a scraping method to coat the workpiece, where the paint is evenly spread by the relative movement of a scraper against the workpiece surface. This scraping method, through the relative movement of the scraper and the workpiece surface, ensures uniform paint distribution, reducing uneven thickness. It allows for precise control of coating thickness; by adjusting the brush pressure and speed, different thicknesses can be achieved. Compared to methods like spraying, scraping is better suited for handling complex surfaces and edges of small workpieces, ensuring complete coverage. Scraping offers high paint utilization, reducing material waste, and is particularly suitable for high-value insulating materials. The pressure during scraping helps the paint better fill tiny depressions and pores on the surface, improving coating density. The scraping process is simple, easily automated, and improves production efficiency and consistency. It is particularly suitable for the precision coating needs of small workpieces in the high-voltage electrical industry, ensuring coating quality while improving production efficiency and material utilization.

[0021] Furthermore, the post-treatment employs hot air drying, where hot air circulation evaporates and cures the coating solvent, resulting in a stable coating. This hot air drying method accelerates the curing process; the hot air circulation rapidly and uniformly heats the coating, accelerating solvent evaporation and coating curing, shortening the production cycle. By controlling temperature and airflow, uniform curing of the coating can be achieved, reducing bubbles and cracks, and improving coating density and smoothness. Appropriate heat treatment can promote cross-linking reactions of coating molecules, improving the coating's insulation performance and heat resistance. The heat treatment process helps the coating form stronger chemical bonds with the workpiece surface, enhancing adhesion and durability. Compared to solvent evaporation, hot air drying can more effectively recover and treat evaporating solvents, reducing environmental pollution. The hot air circulation system improves energy efficiency and reduces production costs. By adjusting temperature and time, hot air drying can adapt to the curing requirements of different types of insulating coatings, increasing process flexibility. It not only ensures high-quality coating curing but also improves production efficiency and environmental friendliness, making it particularly suitable for the high-performance and high-reliability requirements of the high-voltage electrical industry for insulating coatings.

[0022] This invention discloses an insulating material coating for small workpieces. After coating small workpieces with this method, the workpiece achieves multi-dimensional performance improvements. The surface insulation performance of the workpiece is significantly enhanced. Not only does the oxide film provide initial insulation protection, but the uniform and dense insulating coating also meets the stringent insulation requirements of high-voltage electrical equipment. It also possesses excellent corona resistance and heat resistance, adapting to high-voltage operating environments. The adhesion between the coating and the workpiece is greatly improved. After pretreatment, the workpiece surface is clean and contains active groups and a microporous structure, enabling it to form a stable chemical bond and mechanical lock with the insulating coating. Combined with optimized coating and post-treatment, coating peeling and delamination problems are effectively avoided, improving coating durability. The coating quality is highly stable, with uniform coating thickness, free from defects such as uneven thickness, bubbles, and cracks. Excellent density and smoothness reduce interface defects, ensuring stable and reliable insulation performance. The overall service life of the workpiece is extended. The oxide film enhances the corrosion resistance of the workpiece surface, and the high-quality insulating coating further isolates it from external environmental influences, maintaining good performance for a long time. This reduces the maintenance cost and replacement frequency of small workpieces in high-voltage electrical equipment, perfectly meeting the high-performance and high-reliability requirements of the high-voltage electrical industry for insulating coatings on small workpieces. Detailed Implementation

[0023] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Unless otherwise specified, all embodiments and preferred embodiments mentioned herein can be combined to form new technical solutions.

[0025] Unless otherwise specified, all the technical features and preferred features mentioned herein can be combined to form new technical solutions.

[0026] In this invention, unless otherwise specified, percentage (%) or parts refer to weight percentage or parts relative to the composition.

[0027] Unless otherwise specified, the components or preferred components involved in this invention can be combined with each other to form new technical solutions.

[0028] In this invention, unless otherwise specified, the numerical range "a~b" represents a shortened representation of any combination of real numbers between a and b, where a and b are both real numbers. For example, the numerical range "6~22" indicates that all real numbers between "6~22" have been listed in this document, and "6~22" is simply a shortened representation of these numerical combinations.

[0029] The "scope" disclosed in this invention can be in the form of a lower limit and an upper limit, and can be one or more lower limits and one or more upper limits, respectively.

[0030] In this invention, the term "and / or" as used herein refers to any combination of one or more of the associated listed items, as well as all possible combinations, and includes such combinations.

[0031] In this invention, unless otherwise stated, the various reactions or operation steps may be performed sequentially or in a particular order. Preferably, the reaction methods described herein are performed sequentially.

[0032] Unless otherwise stated, the technical and scientific terms used herein have the same meanings as those familiar to those skilled in the art. Furthermore, any methods or materials similar to or equivalent to those described herein may also be used in this invention.

[0033] The embodiments of the present invention will be described in detail below with reference to the examples.

[0034] This invention discloses a method for coating small workpieces with insulating material; comprising: Step 1: Workpiece pretreatment; Step 101: Place the small high-voltage electrical workpiece into the ultrasonic treatment equipment and use 30-40kHz ultrasonic waves to clean and activate the surface of the workpiece to remove oil, impurities and oxide layer. The treatment time is 3-4 minutes. Step 102: Immediately perform anodizing treatment. Oxidize the workpiece surface under a DC voltage of 10-15V to form an oxide film with a microporous structure. The treatment time is 15-20 minutes. Step 103: Clean the treated workpiece with deionized water and air dry it at 60-70℃ for later use.

[0035] Step 2: Prepare the insulating coating; Step 201: Weigh the following raw materials according to the mass ratio: 70-75 parts rubber matrix, 20-25 parts solvent, and 5-10 parts additives; Step 202: Stir for 5 minutes at 1000-1500 rpm using a high-speed mixer at room temperature; Step 203: Turn on the ultrasonic disperser with a power of 200-300W and disperse at a frequency of 40-50kHz for 15 minutes to make the coating evenly mixed. Step 204: Remove air bubbles from the coating using a vacuum degasser to ensure the uniformity and stability of the coating.

[0036] Step 3, coating operation; Step 301: Load the prepared insulating coating into the coating equipment, set the coating thickness to 50-100μm, the coating speed to 0.5-1.5m / min, the coating flow rate to 50-100mL / min, and the pressure to 0.1-0.3MPa; Step 302: The coating is drawn from the storage container by a diaphragm pump and delivered to the coating head through pipeline; Step 303: The coating head applies coating to the workpiece using a scraping method. Under pressure, the coating paint flows out from the coating pen and falls onto the surface of the workpiece. The relative movement between the coating pen and the workpiece surface evenly scrapes the coating paint. Step 304: Set up pressure and flow sensors to monitor the coating pressure and flow rate in real time. When the pressure deviation is greater than ±0.01MPa or the flow rate deviation is greater than ±5mL / min, the control system will automatically adjust the pump output pressure or speed. Step 305: Check the temperature and humidity during the coating process every 30 minutes, keeping the temperature at 20-25℃ and the relative humidity at 40-50%.

[0037] Step 4: Post-processing.

[0038] Step 401: Transfer the coated workpiece to the leveling station using a robotic arm; Step 402: Use hot air drying equipment to dry at a temperature of 120-150℃ for 1-3 hours to allow the coating solvent to fully evaporate and cure; Step 403: Set up a hot air circulation system, with the temperature controlled at 80-100℃ and the number of circulations at 3-5 times, to promote the densification and stabilization of the coating. Step 404: Use a visual inspection system to inspect the coating thickness and uniformity. If uneven coating thickness or missed coating is detected, immediately issue an alarm signal and record the defect location. The control system will automatically adjust the coating parameters to recoat the coating.

[0039] This invention significantly improves the adhesion between insulating materials and workpieces through a pretreatment method combining ultrasonic treatment and anodizing, enhancing the reliability and stability of the coating and meeting the stringent requirements for high reliability and stability of insulating coatings under high-voltage environments. By precisely blending the three main components of the insulating rubber and employing a combination of high-speed stirring and ultrasonic dispersion, uniform coating mixing is ensured, effectively improving the coating's insulation and corona resistance, meeting the stringent requirements of high-voltage electrical equipment for insulating materials. By setting parameters such as coating thickness, speed, coating flow rate, and pressure during the coating process and employing a real-time monitoring and automatic adjustment system, precise control and automation of the coating process are achieved, significantly improving coating uniformity and quality, reducing the frequency of manual intervention, and enhancing production efficiency. The post-treatment method combining hot air drying and hot air circulation allows the coating solvent to fully evaporate and solidify, forming a stable coating, effectively avoiding coating defects during the drying process in traditional processes and extending the equipment's service life. Throughout the coating process, the cooperation of real-time monitoring systems such as pressure sensors and flow sensors, along with a visual inspection system, enables full monitoring of the coating process, timely detection and handling of coating defects, and improved product qualification rates.

[0040] This invention discloses a coating insulating material for small workpieces. The rubber matrix, solvent and additives are mixed by high-speed stirring and ultrasonic dispersion, followed by vacuum degassing to obtain the coating insulating material for small workpieces. The method of this invention for coating small workpieces with insulating materials enables them to achieve excellent performance that meets the stringent standards of the high-voltage electrical industry. Insulation performance is significantly improved; the insulating coating formed on the workpiece surface possesses both good insulation strength and corona resistance. Combined with the initial insulation effect of the anodic oxide film, it meets the operational insulation requirements of high-voltage electrical equipment. Furthermore, after hot air drying and optimized curing, the coating's heat resistance is enhanced, enabling it to adapt to high-voltage operating environments. Coating adhesion and durability are greatly improved. After ultrasonic cleaning and activation followed by anodic oxidation, the surface-active groups and microporous structure of the workpiece form a stable chemical bond and mechanical lock with the insulating coating, effectively preventing coating peeling and ensuring long-term stability. The coating quality exhibits excellent stability. Through precise control of the coating process and uniform hot air curing, the coating thickness is uniform, free of defects such as bubbles and cracks, and exhibits good density and smoothness, avoiding fluctuations in insulation performance caused by coating defects. The service life of the workpiece is extended. The anodic oxide film improves the surface corrosion resistance of the workpiece, and combined with the protective effect of the high-quality insulating coating, it effectively isolates it from external environmental erosion, reducing maintenance costs and replacement frequency for small workpieces in high-voltage electrical equipment.

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. The components of the embodiments of the present invention described and shown herein can be arranged and designed in various different configurations. Therefore, the detailed description of the embodiments of the present invention provided below is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0042] Example 1 A method for coating a small workpiece with an insulating material; comprising: Step 1, Workpiece pretreatment: Step 101: Place the small high-voltage electrical workpiece into the ultrasonic treatment equipment and use 35kHz ultrasonic waves to clean and activate the surface of the workpiece to remove oil, impurities and oxide layer. The treatment time is 3.5 minutes. Step 102: Immediately perform anodizing treatment. Oxidize the workpiece surface under a DC voltage of 12V to form an oxide film with a microporous structure. The treatment time is 18 minutes. Step 103: Clean the treated workpiece with deionized water and air dry it at 65°C for later use.

[0043] Step 2, Insulating Coating Preparation: Step 201: Weigh the following raw materials according to the mass ratio: 72 parts rubber matrix, 22 parts solvent, and 8 parts additives; Step 202: Stir at 1200 rpm for 5 minutes at room temperature using a high-speed mixer; Step 203: Turn on the ultrasonic disperser with a power of 250W and disperse at a frequency of 45kHz for 15 minutes to make the coating evenly mixed. Step 204: Remove air bubbles from the coating using a vacuum degasser to ensure the uniformity and stability of the coating.

[0044] Step 3, Coating Operation: Step 301: Load the prepared insulating coating into the coating equipment, set the coating thickness to 70μm, the coating speed to 1.0m / min, the coating flow rate to 80mL / min, and the pressure to 0.2MPa; Step 302: The coating is drawn from the storage container by a diaphragm pump and delivered to the coating head through pipeline; Step 303: The coating head applies coating to the workpiece using a scraping method. Under pressure, the coating paint flows out from the coating pen and falls onto the surface of the workpiece. The relative movement between the coating pen and the workpiece surface evenly scrapes the coating paint. Step 304: Set up pressure and flow sensors to monitor the coating pressure and flow rate in real time. When the pressure deviation is greater than ±0.015MPa or the flow rate deviation is greater than ±8mL / min, the control system will automatically adjust the pump output pressure or speed. Step 305: Check the temperature and humidity during the coating process every 30 minutes, maintaining the temperature at 22°C and the relative humidity at 45%.

[0045] Step 4, Post-processing: Step 401: Transfer the coated workpiece to the leveling station using a robotic arm; Step 402: Use hot air drying equipment to dry at 130℃ for 2 hours to allow the paint solvent to fully evaporate and cure; Step 403: Set up a hot air circulation system, control the temperature at 90℃, and circulate 4 times to promote the densification and stabilization of the coating. Step 404: Use a visual inspection system to inspect the coating thickness and uniformity. If uneven coating thickness or missed coating is detected, immediately issue an alarm signal and record the defect location. The control system will automatically adjust the coating parameters to recoat the coating.

[0046] Example 2 A method for coating a small workpiece with an insulating material; comprising: Step 1, Workpiece pretreatment: Step 101: Place the small high-voltage electrical workpiece into the ultrasonic treatment equipment and use 40kHz ultrasonic waves to clean and activate the surface of the workpiece to remove oil, impurities and oxide layer. The treatment time is 4 minutes. Step 102: Immediately perform anodizing treatment. Oxidize the workpiece surface under a DC voltage of 15V to form an oxide film with a microporous structure. The treatment time is 20 minutes. Step 103: Clean the treated workpiece with deionized water and air dry it at 70°C for later use.

[0047] Step 2, Insulating Coating Preparation: Step 201: Weigh the following raw materials according to the mass ratio: 75 parts rubber matrix, 25 parts solvent, and 10 parts additive; Step 202: Stir at 1500 rpm for 5 minutes using a high-speed mixer at room temperature; Step 203: Turn on the ultrasonic disperser with a power of 300W and disperse at a frequency of 50kHz for 15 minutes to make the coating evenly mixed. Step 204: Remove air bubbles from the coating using a vacuum degasser to ensure the uniformity and stability of the coating.

[0048] Step 3, Coating Operation: Step 301: Load the prepared insulating coating into the coating equipment, set the coating thickness to 100μm, the coating speed to 1.5m / min, the coating flow rate to 100mL / min, and the pressure to 0.3MPa; Step 302: The coating is drawn from the storage container by a diaphragm pump and delivered to the coating head through pipeline; Step 303: The coating head applies coating to the workpiece using a scraping method. Under pressure, the coating paint flows out from the coating pen and falls onto the surface of the workpiece. The relative movement between the coating pen and the workpiece surface evenly scrapes the coating paint. Step 304: Set up pressure and flow sensors to monitor the coating pressure and flow rate in real time. When the pressure deviation is greater than ±0.02MPa or the flow rate deviation is greater than ±7mL / min, the control system will automatically adjust the pump output pressure or speed. Step 305: Check the temperature and humidity during the coating process every 30 minutes, keeping the temperature at 25°C and the relative humidity at 50%.

[0049] Step 4, Post-processing: Step 401: Transfer the coated workpiece to the leveling station using a robotic arm; Step 402: Use hot air drying equipment to dry at 150℃ for 3 hours to allow the paint solvent to fully evaporate and cure; Step 403: Set up a hot air circulation system, control the temperature at 100℃, and circulate 5 times to promote the densification and stabilization of the coating. Step 404: Use a visual inspection system to inspect the coating thickness and uniformity. If uneven coating thickness or missed coating is detected, immediately issue an alarm signal and record the defect location. The control system will automatically adjust the coating parameters to recoat the coating.

[0050] Example 3 A method for coating a small workpiece with an insulating material; comprising: Step 1, Workpiece pretreatment: Step 101: Place the small high-voltage electrical workpiece into the ultrasonic treatment equipment and use 30kHz ultrasonic waves to clean and activate the surface of the workpiece to remove oil, impurities and oxide layer. The treatment time is 3 minutes. Step 102: Immediately perform anodizing treatment. Oxidize the workpiece surface under a DC voltage of 10V to form an oxide film with a microporous structure. The treatment time is 15 minutes. Step 103: Clean the treated workpiece with deionized water and air dry it at 60°C for later use.

[0051] Step 2, Insulating Coating Preparation: Step 201: Weigh the following raw materials according to the mass ratio: 70 parts rubber matrix, 20 parts solvent, and 10 parts additive; Step 202: Stir at 1000 rpm for 5 minutes at room temperature using a high-speed mixer; Step 203: Turn on the ultrasonic disperser with a power of 200W and disperse at a frequency of 40kHz for 15 minutes to make the coating evenly mixed. Step 204: Remove air bubbles from the coating using a vacuum degasser to ensure the uniformity and stability of the coating.

[0052] Step 3, Coating Operation: Step 301: Load the prepared insulating coating into the coating equipment, set the coating thickness to 50μm, the coating speed to 0.5m / min, the coating flow rate to 50mL / min, and the pressure to 0.1MPa; Step 302: The coating is drawn from the storage container by a diaphragm pump and delivered to the coating head through pipeline; Step 303: The coating head applies coating to the workpiece using a scraping method. Under pressure, the coating paint flows out from the coating pen and falls onto the surface of the workpiece. The relative movement between the coating pen and the workpiece surface evenly scrapes the coating paint. Step 304: Set up pressure and flow sensors to monitor the coating pressure and flow rate in real time. When the pressure deviation is greater than ±0.02MPa or the flow rate deviation is greater than ±7mL / min, the control system will automatically adjust the pump output pressure or speed. Step 305: Check the temperature and humidity during the coating process every 30 minutes, keeping the temperature at 20°C and the relative humidity at 50%.

[0053] Step 4, Post-processing: Step 401: Transfer the coated workpiece to the leveling station using a robotic arm; Step 402: Use hot air drying equipment to dry at 120℃ for 1 hour to allow the paint solvent to fully evaporate and cure; Step 403: Set up a hot air circulation system, control the temperature at 80℃, and circulate 3 times to promote the densification and stabilization of the coating. Step 404: Use a visual inspection system to inspect the coating thickness and uniformity. If uneven coating thickness or missed coating is detected, immediately issue an alarm signal and record the defect location. The control system will automatically adjust the coating parameters to recoat the coating.

[0054] In summary, the present invention discloses a method for coating small workpieces with insulating materials, employing ultrasonic treatment technology to clean and activate the workpiece surface. Anodizing is performed on the metal workpiece surface to form a microporous oxide film. The insulating coating formula, including a rubber matrix, solvent, and additives, is precisely formulated. A combination of high-speed stirring and ultrasonic dispersion ensures uniform coating mixing. Parameters such as coating thickness, speed, coating flow rate, and pressure are set. A diaphragm pump and pipeline system stably supply the coating. After coating the workpiece using a scraping method, leveling is performed, followed by hot air drying, where hot air circulation evaporates and solidifies the coating solvent. Pressure and flow sensors are used to monitor the coating pressure and flow rate in real time. Algorithms are used to adjust coating parameters promptly, and a visual inspection system is incorporated to check the coating effect and provide timely alarms or adjustments.

[0055] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0056] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A method for coating a small workpiece with an insulating material, characterized in that, include: 1) An insulating coating is obtained by mixing a rubber matrix, solvent, and additives through high-speed stirring and ultrasonic dispersion, followed by vacuum degassing; the rubber matrix is ​​high-temperature resistant silicone rubber; the solvent is xylene; and the additives include crosslinking agents and flame retardants. 2) Load the insulating coating into the coating equipment. During the coating process, monitor and adjust the coating thickness, speed, coating flow rate and pressure in real time. The insulating coating is delivered to the coating pen through the diaphragm pump. The coating pen moves relative to the pretreated workpiece surface to evenly scrape the insulating coating. After post-processing, small workpieces are coated with insulating material.

2. The method for coating small workpieces with insulating material according to claim 1, characterized in that, In step 1), the mass ratio of the rubber matrix, solvent and additive is (70-75):(20-25):(5-10).

3. The method for coating small workpieces with insulating material according to claim 1, characterized in that, In step 1), the conditions for high-speed stirring include: stirring at 1000-1500 rpm for 5 minutes; The conditions for ultrasonic dispersion include: turning on an ultrasonic disperser with a power of 200-300W and dispersing at a frequency of 40-50kHz for 15 minutes.

4. The method for coating small workpieces with insulating material according to claim 1, characterized in that, In step 2), the pretreatment conditions for the workpiece include: performing ultrasonic cleaning and activation and anodizing treatment on the workpiece in sequence to form a microporous oxide film, and then cleaning and drying; the ultrasonic treatment frequency is 30-40kHz and the time is 3-4 minutes; and anodizing is performed for 15-20 minutes under a DC voltage of 10-15V.

5. The method for coating insulating material onto small workpieces according to claim 1, characterized in that, In step 2), the coating conditions include: coating thickness of 50-100 μm, coating speed of 0.5-1.5 m / min, coating flow rate of 50-100 mL / min, and pressure of 0.1-0.3 MPa.

6. The method for coating insulating material onto small workpieces according to claim 1, characterized in that, In step 2), during the coating process, the pressure sensor monitors the coating pressure in real time. When the pressure deviation is large, the control system automatically adjusts the pump output pressure. The flow sensor monitors the coating flow in real time. When the flow deviation is large, the control system automatically adjusts the pump speed. The vision inspection system periodically takes pictures of the coated workpiece for inspection. If uneven coating thickness or missed coating is detected, an alarm signal is immediately issued and fed back to the control system. The control system stops the equipment operation and records the defect location. The defect is then manually handled or the equipment automatically adjusts the coating parameters for recoating.

7. The method for coating insulating material onto small workpieces according to claim 6, characterized in that, In step 2), automatic adjustment is performed when the pressure deviation is greater than ±0.01MPa or the flow rate deviation is greater than ±5mL / min.

8. The method for coating insulating material onto small workpieces according to claim 1, characterized in that, In step 2), the coating environment temperature is controlled at 20-25℃ and the relative humidity is 40%-50%, and the test is performed every 30 minutes.

9. The method for coating insulating material onto small workpieces according to claim 1, characterized in that, In step 2), the post-processing includes: transferring the workpiece to the leveling station by a robot for leveling, drying with hot air and curing with hot air circulation, and finally performing visual inspection of the coating; the temperature of the hot air drying is 120-150℃ and the time is 1-3 hours; the temperature of the hot air circulation is 80-100℃ and the circulation is 3-5 times.

10. The insulating material for coating small workpieces used in the method of coating insulating material for small workpieces according to any one of claims 1 to 9, characterized in that, include: 70-75 parts rubber matrix, 20-25 parts solvent, and 5-10 parts additives.