Water-cooled plasma spray gun system for long-time efficient wire / powder spraying

Abstract

The invention discloses a water-cooled plasma spray gun system for long-time efficient wire / powder spraying. The water-cooled plasma spray gun system comprises a plasma spray gun; the insulating plate is detachably arranged on one side of the plasma spray gun, and the insulating plate can rotate relative to the plasma spray gun; the water cooling support is detachably arranged on the other side, opposite to the plasma spray gun, of the insulating plate, and the water cooling support can transversely move relative to the insulating plate; and the wire feeding device is detachably arranged at one end of the water cooling support, and the wire feeding device is selectively arranged opposite to the jet flow of the plasma spray gun. The device has the characteristics that the position of the metal wire can be conveniently corrected, the low-temperature state of the wire feeding structure is effectively guaranteed, and the spraying efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of plasma spraying technology, and more specifically, to a water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder. Background Technology

[0002] Plasma-enhanced high-speed arc spraying combines the advantages of both supersonic plasma spraying and arc spraying. It possesses the advantages of supersonic plasma spraying, such as high heat source temperature, concentrated jet energy density, and a wide range of applicable materials, while also having the advantages of arc spraying, such as high operating efficiency, low energy cost, and wide spraying area. Furthermore, it integrates powder spraying and wire spraying into one unit, achieving simultaneous wire / powder spraying, which is of great significance for improving spraying efficiency and coating quality.

[0003] Patents CN109594033B, CN117737640A, CN114086106A, and CN109695013B provide a relatively detailed description of the spraying system. Among them, CN109695013B describes the wire feeding system of the spraying system as including: a wire feeder, a wire feeding hose, and a wire feeding connector. The output end of the wire feeder is connected to the wire feeding hose, and the wire feeding hose is connected to the wire feeding connector. The metal wire is fed from the wire feeder through the wire feeding hose and the wire feeding connector to the front of the nozzle. The wire feeding connector is connected to the positive terminal of the power supply.

[0004] It should be noted that because the plasma jet temperature of this spraying system is extremely high (reaching over 10,000℃), the wire feeding device (wire feeder and wire feed nozzle) and the wire itself are both in an extremely high-temperature environment. This results in four main disadvantages: First, the wire feeding device and the wire transfer heat to the wire feeding hose behind it, easily causing the hose to be exposed to high temperatures and burn its plastic components. Second, the wire and wire feed nozzle experience thermal expansion and contraction, reducing the nozzle's orifice size and affecting the stability of the wire feeding (when the wire feeding rate is unstable). (1) At certain times, the electric arc at the tip of the wire will jump, causing instability or arc breakage in the jet. (2) The spraying system requires the metal wire to be in the exact center of the plasma jet and in a suitable position with the nozzle end face. Therefore, the position of the metal wire must be corrected before the spraying operation. The current wire feeding system has shortcomings such as complicated adjustment process. (3) When the metal wire feeding device (wire feeder and wire feed nozzle) is in an extremely high temperature environment for a long time, its own temperature will also be high (>200℃). If arc breakage occurs and the wire feed nozzle needs to be replaced, it will cause burns to the operator.

[0005] To address the shortcomings of the current wire feeding system in plasma-enhanced high-speed arc spraying systems regarding the metal feeding device, structural optimization design is needed to better suit the implementation of spraying operations. Summary of the Invention

[0006] The purpose of this invention is to design and develop a water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder. The system integrates the wire feeding device and the water-cooling circulation system with the plasma spray gun, enabling convenient correction of the metal wire and effectively ensuring the low-temperature state of the wire feeding device.

[0007] The technical solution provided by this invention is as follows: A water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder includes: Plasma spray gun; and An insulating plate is detachably disposed on one side of the plasma spray gun, and the insulating plate is rotatable relative to the plasma spray gun; A water-cooled bracket is detachably mounted on the other side of the insulating plate opposite to the plasma spray gun, and the water-cooled bracket can move laterally relative to the insulating plate. A filament feeding device is detachably mounted on one side of the water-cooled bracket, and the filament feeding device can be selectively positioned opposite to the jet of the plasma spray gun.

[0008] Preferably, it also includes: An insulating frame, which is detachably mounted on the plasma spray gun; A cathode terminal block is detachably mounted on the insulating frame and is connected to the cathode water cable connecting rod of the plasma spray gun for connection to the power cathode cable.

[0009] Preferably, it also includes: A cathode water cable adapter, which is connected to the cathode water cable connecting rod of the plasma spray gun; The cathode junction box is located between the cathode water cable adapter and the cathode water cable connecting rod of the plasma spray gun.

[0010] Preferably, it also includes: The first adjusting bolt is detachably fixed between one end of the insulating plate and one side of the plasma spray gun; The first slide is located at the other end near the insulating plate. The first slide is arc-shaped and the center of the arc is the first adjusting bolt. The second adjusting bolt is detachably fixed between the insulating plate and one side of the plasma spray gun, and the second adjusting bolt can be selectively slidable or fixed in the first groove. The second slide is located at one end of the insulating plate near the first adjusting bolt, and the second slide is arc-shaped with the first adjusting bolt as its center. The third adjusting bolt is detachably fixed between the insulating plate and one side of the plasma spray gun, and the third adjusting bolt can be selectively slidable or fixed in the second groove.

[0011] Preferably, it also includes: Two third sliding grooves are symmetrically arranged at one end of the water-cooling bracket; Two fourth adjusting bolts are detachably fixed between the water-cooling bracket and the insulating plate, and the two fourth adjusting bolts can be selectively slid or fixed in the two third sliding grooves. The fourth chute is located at the other end of the water-cooling bracket; The fifth adjusting bolt is detachably fixed between the water-cooling bracket and the insulating plate, and the fifth adjusting bolt can be selectively slidable or fixed in the fourth sliding groove.

[0012] Preferably, it also includes: A large anode water cable connector is provided on the other side of the water-cooling bracket, and the large anode water cable connector can be selectively connected to the large anode water cable; A water-cooled outlet connector is located on the other side of the water-cooled support, and the water-cooled outlet connector is connected to the large anode water cable connector inside the water-cooled support for cooling the wire feeding device.

[0013] Preferably, the water-cooled outlet connector and the cathode water cable adapter are connected via an external water pipe.

[0014] Preferably, the filament feeding device includes: A water-cooled wire feeder is detachably mounted on one side of the water-cooled bracket, and the water-cooled wire feeder is connected to the wire feeder tube. The fastening nut is fixed between the water-cooled wire feed head and the water-cooled bracket to secure the water-cooled wire feed head.

[0015] Preferably, the maximum angle at which the insulating plate can rotate relative to the plasma spray gun is ±10°.

[0016] Preferably, the water-cooled bracket can move laterally relative to the insulating plate by a distance ranging from 1 to 20 mm.

[0017] The beneficial effects of this invention are as follows: (1) The present invention designs and develops a water-cooled plasma spray gun system for long-term high-efficiency spraying of wire / powder, which integrates the metal wire feeding device and the plasma spray gun into one design, simplifying the overall structure and facilitating the correction of the position of the metal wire before spraying.

[0018] (2) The water-cooled plasma spray gun system designed and developed by the present invention for long-term high-efficiency spraying of wire / powder uses water cooling to cool the metal wire feeding device, effectively ensuring that the wire feeding head is always in a low temperature state, protecting the wire feeding hose and other related plastic structural components in the wire feeding system, ensuring a long-term stable supply of metal wire during the spraying operation, ensuring the long-term high-efficiency operation of the spraying system, and improving the spraying efficiency.

[0019] (3) The water-cooled plasma spray gun system designed and developed by the present invention for long-term high-efficiency spraying of wire / powder has a wire feeding device whose position can be adjusted by rotation or lateral movement to ensure that the wire feeding nozzle corresponds to the jet center of the plasma spray gun at all times. At the same time, it can ensure the safety of operators when inspecting and replacing parts such as the wire feeding nozzle during the spraying interval, and can effectively avoid high temperature burns. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in this invention.

[0021] Figure 2 This is a schematic diagram of the assembly structure of the plasma spray gun described in this invention.

[0022] Figure 3 This is a schematic diagram of the assembly structure of the insulating plate and water-cooling bracket described in this invention.

[0023] Figure 4 This is a cross-sectional structural diagram of the water-cooled support described in this invention.

[0024] Figure 5 This is a schematic diagram of the assembly structure of the insulating board described in this invention.

[0025] Figure 6 This is a schematic diagram of the structure of the water-cooled support described in this invention.

[0026] Figure 7 This is an integrated physical diagram of the water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in this invention.

[0027] Figure 8 This is a breakdown diagram of the water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in this invention. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0029] like Figures 1-6 As shown, the water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder provided by the present invention includes: Plasma spray gun 100, cathode terminal block 120, insulating frame 130, insulating plate 140, water-cooled bracket 150, and wire feeding device 160; The plasma spray gun 100 integrates a cathode water cable connecting rod, a high-pressure mixed gas interface, and a water outlet and small anode interface. A cathode connecting cap 111 is provided at the far end of the cathode water cable connecting rod, a water outlet and small anode connector 101 is provided at the far end of the water outlet and small anode interface, and a high-pressure mixed gas pipe connector 102 is provided at the far end of the high-pressure mixed gas interface for connecting with an external high-pressure mixed gas.

[0030] In this embodiment, the plasma spray gun 100 is a CYS-4E plasma spray gun assembly.

[0031] The insulating frame 130 is detachably mounted on the plasma spray gun 100 by bolts, and the cathode terminal block 120 is detachably connected to the insulating frame 130 by cathode terminal block fastening bolts 121, and the cathode terminal block fastening bolts 121 are connected to the power cathode cable.

[0032] The cathode connection cap 111 is connected to the cathode water cable adapter 113, and the cathode water cable adapter 113 is pressed onto the cathode terminal plate 120 by the cathode terminal plate clamping cap 112, that is, the cathode terminal plate 120 is located between the cathode water cable adapter 113 and the cathode terminal plate clamping cap 112.

[0033] The insulating plate 140 is detachably disposed on one side of the plasma spray gun 100, and the insulating plate 140 can rotate relative to the plasma spray gun 100; the water-cooling bracket 150 is detachably disposed on the other side of the insulating plate relative to the plasma spray gun 100, that is, the water-cooling bracket 150 and the plasma spray gun 100 are respectively disposed on both sides of the insulating plate 140, and the water-cooling bracket 150 can move laterally relative to the insulating plate 140.

[0034] A wire feeding device 160 is provided on one side of the water-cooled support 150, and the wire feeding device 160 can be selectively arranged opposite to the jet of the plasma spray gun 100. A large anode water cable connector 151 and a water-cooled outlet connector 152 are provided on the other side of the water-cooled support 150. The large anode water cable connector 151 can be selectively connected to the large anode water cable. The water-cooled outlet connector 152 is connected to the large anode water cable connector 151 inside the water-cooled support 150 and flows through the wire feeding device 160 for cooling the wire feeding device 160.

[0035] In this embodiment, a first adjusting bolt 141 is detachably provided on the side of the insulating plate 140 near the water-cooling bracket 150 for fixing the insulating plate 140 to one side of the plasma spray gun 100. A first sliding groove 142 and a second sliding groove 144 are provided on the insulating plate 140. The first sliding groove 142 is located at the other end near the insulating plate 140, and the second sliding groove 144 is located at the end of the insulating plate 140 near the first adjusting bolt 141. Both the first sliding groove 142 and the second sliding groove 144 are arc-shaped, and the center of the arc is the first adjusting bolt 141. A second adjusting bolt 143 is provided in the first sliding groove 142, and the second adjusting bolt 143 can be slidably or fixedly in the first sliding groove 142. A third adjusting bolt 145 is provided in the second sliding groove 144, and the third adjusting bolt 145 can be slidably or fixedly in the second sliding groove 144.

[0036] In this embodiment, the insulating plate 140 can rotate relative to the plasma spray gun 100 by an angle of ±10°.

[0037] The water-cooled bracket 150 is provided with two third sliding grooves 181 and a fourth sliding groove 183. The two third sliding grooves 181 are symmetrically arranged at one end of the water-cooled bracket 150. The fourth sliding groove 183 is arranged at the other end of the water-cooled bracket 150 to ensure the lateral movement stability of the water-cooled bracket 150. A fourth adjusting bolt 182 is provided in each of the two third sliding grooves 181. The fourth adjusting bolt 182 can be slidable or fixed in the third sliding groove 181. A fifth adjusting bolt 184 is provided in the fourth sliding groove 183. The fifth adjusting bolt 184 can be slidable or fixed in the fourth sliding groove 183.

[0038] In this embodiment, with the nozzle end face as a reference, the water-cooling bracket 150 can move laterally relative to the insulating plate 140 by a distance ranging from 1 to 20 mm.

[0039] The wire feeding device includes a water-cooled wire feeding head 161 and a fastening nut 162. The water-cooled wire feeding head 161 passes through a hole on one side of the water-cooled bracket 150 and is then fixed by the fastening nut 162. The water-cooled wire feeding head 161 is connected to the wire feeding tube (which belongs to other external mechanisms). The water-cooled wire feeding head 161 and the water-cooled bracket 150 are sealed by two rubber rings.

[0040] The cathode water cable adapter 113 is connected to the water-cooled outlet connector 152 via an external water pipe. That is, the cooling process of the water-cooled plasma spray gun system for long-term high-efficiency spraying of wire / powder described in this invention is as follows: cooling water enters through the large anode water cable connector 151, then exits through the water-cooled outlet connector 152, and then enters the cathode water cable adapter 113 through the external water pipe. After flowing through the plasma spray gun 100, it flows out through the outlet and the small anode connector 101.

[0041] The working modes of the water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder described in this invention include: Mode 1: After correctly connecting the water circuit, electrical circuit and other equipment of the spraying system, first use the spraying system control platform to turn on the cooling water circulation switch and ensure that the cooling water circulation system is working normally. Then, perform arc and debugging operations according to the normal plasma spraying process. After the debugging is completed, only the small anode (i.e., the anode nozzle, which is connected to the positive terminal of the small power supply) works, so that a non-transferring plasma arc is formed between the small anode and the cathode. At this time, the function of the plasma spray gun is the same as that of the traditional plasma spray gun.

[0042] Mode 2: Based on Mode 1, the spraying system control platform is used to make the metal wire feeding device work, send out the metal wire, and at the same time turn on the large anode (i.e. the metal wire, which is connected to the positive terminal of the large power supply) switch, so that a plasma transfer arc is formed between the large anode and the cathode. At this time, there are both non-transfer arc and transfer arc in the spraying system, and the metal wire can be sprayed alone or the metal wire and powder can be sprayed at the same time.

[0043] Mode 3: Based on Mode 2, after a plasma transfer arc is formed between the large anode and the cathode, the small anode power switch is disconnected using the spraying system control platform. At this time, only the transfer arc exists in the spraying system, and the metal wire can be sprayed separately.

[0044] Mode 4: After correctly connecting the various subsystems of the spraying system in Mode 2, connect the workpiece to be sprayed to the positive terminal of the third power supply (i.e., the workpiece is the third anode). When Mode 2 is working normally, use the spraying system control platform to turn on the third anode power switch, so that a plasma transfer arc is formed between the third anode and the cathode, thereby forming a molten pool on the surface of the workpiece.

[0045] It should be noted that: Mode 1 can only spray powder materials, Mode 3 can only spray metal wire materials, and Modes 2 and 4 can spray both metal wire materials and powder materials simultaneously; Modes 1 and 3 have only one anode, so the spraying power is lower and the system energy consumption is reduced, while Modes 2 and 4 have two anodes and three anodes respectively, so the spraying power of Modes 2 and 4 is higher and the system energy consumption is higher.

[0046] like Figure 7 , Figure 8The image shown is a physical diagram of the water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder according to the present invention.

[0047] This invention relates to a water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder. The system integrates the wire feeding device with the plasma spray gun into a single unit, simplifying the overall structure and facilitating the alignment of the wire before spraying. Water cooling of the wire feeding device effectively ensures the wire feed head remains at a low temperature, protecting the wire feeding hose and other related plastic components. This ensures a stable and continuous supply of wire during spraying, guaranteeing long-term, high-efficiency operation and improving overall spraying efficiency. The wire feeding device can be adjusted by rotation or lateral movement to ensure the wire feed nozzle always aligns with the jet center of the plasma spray gun. This also ensures operator safety when inspecting or replacing parts such as the wire feed nozzle during spraying breaks, effectively preventing burns from high temperatures.

[0048] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. A water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder, characterized in that, include: Plasma spray gun; as well as An insulating plate is detachably disposed on one side of the plasma spray gun, and the insulating plate is rotatable relative to the plasma spray gun; A water-cooled bracket is detachably mounted on the other side of the insulating plate opposite to the plasma spray gun, and the water-cooled bracket can move laterally relative to the insulating plate. A filament feeding device is detachably mounted on one side of the water-cooled bracket, and the filament feeding device can be selectively positioned opposite to the jet of the plasma spray gun.

2. The water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in claim 1, characterized in that, Also includes: An insulating frame, which is detachably mounted on the plasma spray gun; A cathode terminal block is detachably mounted on the insulating frame and is connected to the cathode water cable connecting rod of the plasma spray gun for connection to the power cathode cable.

3. The water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in claim 2, characterized in that, Also includes: A cathode water cable adapter, which is connected to the cathode water cable connecting rod of the plasma spray gun; The cathode junction box is located between the cathode water cable adapter and the cathode water cable connecting rod of the plasma spray gun.

4. The water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in claim 3, characterized in that, Also includes: The first adjusting bolt is detachably fixed between one end of the insulating plate and one side of the plasma spray gun; The first slide is located at the other end near the insulating plate. The first slide is arc-shaped and the center of the arc is the first adjusting bolt. The second adjusting bolt is detachably fixed between the insulating plate and one side of the plasma spray gun, and the second adjusting bolt can be selectively slidable or fixed in the first groove. The second slide is located at one end of the insulating plate near the first adjusting bolt, and the second slide is arc-shaped with the first adjusting bolt as its center. The third adjusting bolt is detachably fixed between the insulating plate and one side of the plasma spray gun, and the third adjusting bolt can be selectively slidable or fixed in the second groove.

5. The water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in claim 4, characterized in that, Also includes: Two third sliding grooves are symmetrically arranged at one end of the water-cooling bracket; Two fourth adjusting bolts are detachably fixed between the water-cooling bracket and the insulating plate, and the two fourth adjusting bolts can be selectively slid or fixed in the two third sliding grooves. The fourth chute is located at the other end of the water-cooling bracket; The fifth adjusting bolt is detachably fixed between the water-cooling bracket and the insulating plate, and the fifth adjusting bolt can be selectively slidable or fixed in the fourth sliding groove.

6. The water-cooled plasma spray gun system for long-duration, high-efficiency spraying of wire / powder as described in claim 5, characterized in that, Also includes: A large anode water cable connector is provided on the other side of the water-cooling bracket, and the large anode water cable connector can be selectively connected to the large anode water cable; A water-cooled outlet connector is located on the other side of the water-cooled support, and the water-cooled outlet connector is connected to the large anode water cable connector inside the water-cooled support for cooling the wire feeding device.

7. The water-cooled plasma spray gun system for long-duration, high-efficiency spraying of wire / powder as described in claim 6, characterized in that, The water-cooled outlet connector and the cathode water cable adapter are connected via an external water pipe.

8. The water-cooled plasma spray gun system for long-term, high-efficiency spraying of wire / powder as described in claim 7, characterized in that, The wire feeding device includes: A water-cooled wire feeder is detachably mounted on one side of the water-cooled bracket, and the water-cooled wire feeder is connected to the wire feeder tube. The fastening nut is fixed between the water-cooled wire feed head and the water-cooled bracket to secure the water-cooled wire feed head.

9. The water-cooled plasma spray gun system for long-duration, high-efficiency spraying of wire / powder as described in claim 8, characterized in that, The maximum angle at which the insulating plate can rotate relative to the plasma spray gun is ±10°.

10. The water-cooled plasma spray gun system for long-duration, high-efficiency spraying of wire / powder as described in claim 9, characterized in that, The water-cooled bracket can move laterally relative to the insulating plate by a distance ranging from 1 to 20 mm.

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