Improved water-cooled plasma spray gun system for synchronous wire / powder spraying

Abstract

The invention discloses an improved water-cooled plasma spray gun system for wire / powder synchronous spraying. The improved water-cooled plasma spray gun system comprises a plasma spray gun; the insulating base plate is arranged on one side of the plasma spray gun, and the insulating base plate can transversely move relative to the plasma spray gun; the water cooling bracket is arranged on one side, opposite to the plasma spray gun, of the insulating base plate, and the water cooling bracket can rotate relative to the insulating base plate; the water-cooling wire feeding device is detachably arranged at one end of the water-cooling support, and the water-cooling wire feeding device is selectively arranged opposite to the jet flow of the plasma spray gun; wherein the transverse movement of the insulating base plate and the rotation of the water-cooling bracket can be adjusted at the same time. The method has the characteristics that the adjustment process of the metal wire is optimized, the operation efficiency is improved, and the air cooling effect is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of plasma spraying technology, and more specifically, to an improved water-cooled plasma spray gun system for simultaneous wire / powder spraying. Background Technology

[0002] Supersonic plasma spraying can reach heat source temperatures exceeding 10,000℃, offering advantages such as concentrated energy density, a wide range of sprayable materials, and excellent coating quality. However, it suffers from drawbacks including low spraying efficiency, limited operating range, and high energy consumption. Arc spraying, on the other hand, boasts advantages such as high spraying efficiency, low manufacturing cost, and a wide operating range, but suffers from disadvantages such as poor arc stability, lower coating quality, and insufficient particle atomization. Plasma transferred arc wire spraying, by combining supersonic plasma spraying and arc spraying, leverages the advantages of both. On one hand, it utilizes high-energy, high-speed plasma jets to achieve more complete atomization of molten wire droplets while increasing particle flight speed; on the other hand, wire spraying significantly improves spraying efficiency and reduces manufacturing costs.

[0003] Patents CN109594033B, CN117737640A, CN114086106A, and CN109695013B provide a relatively detailed description of the plasma transfer arc wire spraying system. The stable supply of metal wire in this spraying system is of decisive significance to the stability of the spraying operation.

[0004] Patent CN109695013B specifies that the wire feeding system of the spraying system includes: a wire feeder, a wire feeding hose, and a wire feeding connector (i.e., a wire feeding nozzle). 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 main power supply. It is worth noting that, apart from the wire feeder and the wire feeding hose being commercial products, the other components in this wire feeding system (the wire feeding nozzle and the wire feeding nozzle bracket, collectively referred to as the metal wire feeding device) are all self-made and independently designed and manufactured (cooling method: natural cooling or air cooling).

[0005] However, existing plasma transfer arc wire coating systems have many drawbacks: First, the wire feeding device and the wire feeding hose, which transfer heat from the wire to the hose, are prone to overheating and burning the hose's plastic components. Second, the wire and the feeding nozzle expand and contract with heat, reducing the nozzle's orifice size and affecting feeding stability (when the wire feeding rate is unstable, the arc at the wire tip will jump, causing jet instability or arc breakage). Third, this spraying system requires the wire to be centered on the plasma jet and positioned appropriately with the nozzle end face; therefore, the wire's position must be corrected before spraying, but current systems have drawbacks such as complex calibration processes. Fourth, when the wire feeding device (feeding frame and feeding 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 feeding nozzle needs to be replaced, it will cause burns to the operator.

[0006] To address the shortcomings of existing plasma transfer arc wire spraying systems, there is an urgent need for structural optimization design to improve the efficiency and safety of the spraying process. Summary of the Invention

[0007] The purpose of this invention is to design and develop an improved water-cooled plasma spray gun system for simultaneous filament / powder spraying. By combining an insulating pad and a water-cooled bracket, the distance between the filament and the nozzle end face and the deflection angle between the filament and the jet can be adjusted synchronously, and the stability of the spraying process can be ensured by water cooling.

[0008] The technical solution provided by this invention is as follows: An improved water-cooled plasma spray gun system for simultaneous wire / powder spraying includes: Plasma spray gun; and An insulating pad is disposed on one side of the plasma spray gun, and the insulating pad is movable laterally relative to the plasma spray gun. A water-cooled bracket is disposed on one side of the insulating pad relative to the plasma spray gun, and the water-cooled bracket is rotatable relative to the insulating pad. A water-cooled wire feeding device is detachably mounted at one end of the water-cooled bracket, and the water-cooled wire feeding device can be selectively positioned opposite to the jet of the plasma spray gun. The lateral movement of the insulating pad and the rotation of the water-cooling bracket can be adjusted simultaneously.

[0009] Preferably, it also includes: A powder feeding integrated device is installed at the nozzle of the plasma spray gun.

[0010] Preferably, it also includes: At least two first grooves are respectively disposed at both ends of the insulating pad; At least two first adjusting bolts are disposed between the insulating pad and the plasma spray gun, and the at least two first adjusting bolts are respectively selectably slidable or fixed in at least two first grooves.

[0011] Preferably, the water-cooling bracket includes: A fixing plate, which is rotatably disposed on one side of the insulating pad; The frame is integrated with the fixing plate, and the frame is a cavity structure; A first water-cooling passage is provided inside the frame and flows through the water-cooled wire feeding device. The first water-cooling pipe quick connector is located at the other end of the frame and is connected to one end of the first water-cooling passage. The second water-cooling pipe quick connector is located at the other end of the frame and is connected to the other end of the first water-cooling passage. The water-cooled wire feeding device passes through one end of the frame, and the fixing plate is away from at least two first sliding grooves and at least two first adjusting bolts.

[0012] Preferably, the water-cooling bracket further includes: A large anode connection threaded hole is provided on the frame for connecting to the large anode of the power supply.

[0013] Preferably, it also includes: The second water-cooling passage is located inside the plasma spray gun and is used to cool the gun body. The third water-cooling passage is located inside the plasma spray gun and is used to cool the gun body; The third water-cooling quick-connect connector is connected to one end of the second water-cooling passage. The fourth water-cooling quick-connect connector is connected to one end of the third water-cooling passage; The other end of the second water-cooling passage is connected to the anode water cable connector of the plasma spray gun, and the other end of the third water-cooling passage is connected to the cathode water cable connector.

[0014] Preferably, the anode water cable connector is connected to the water outlet of the water chiller, the cathode water cable connector is connected to the water inlet of the water chiller, and the third and fourth water cooling quick-connect connectors are respectively connected to the first or second water cooling pipe quick-connect connector.

[0015] Preferably, it also includes: The second adjusting bolt is fixed between the frame and the insulating pad; Two second sliding grooves are symmetrically arranged on both sides of one end of the fixed plate. Both second sliding grooves are arc-shaped and the center of the arc is the second adjusting bolt. Two third adjusting bolts are detachably fixed between the fixing plate and the insulating pad, and the two third adjusting bolts can be selectively slid or fixed in the two second sliding grooves respectively.

[0016] Preferably, the insulating pad is positioned relative to the plasma spray gun and can move laterally by 1-20 mm relative to the plasma spray gun, with the nozzle end face of the plasma spray gun as a reference.

[0017] Preferably, the water-cooled bracket can rotate ±10° relative to the insulating pad, with the nozzle of the plasma spray gun as a reference.

[0018] The beneficial effects of this invention are as follows: (1) The present invention designs and develops an improved water-cooled plasma spray gun system for simultaneous wire / powder spraying, which optimizes the adjustment process of metal wire and can simultaneously adjust the distance between the wire and the nozzle end face and the deflection angle between the wire and the jet, making it easier for operators to adjust the position of the wire more quickly and accurately, which is beneficial to improving work efficiency.

[0019] (2) The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying designed and developed in this invention optimizes the overall structure of the system, making the spraying system simpler and more efficient, and facilitating later maintenance and updates.

[0020] (3) The present invention designs and develops an improved water-cooled plasma spray gun system for simultaneous wire / powder spraying. It adopts a highly efficient water cooling method, which is more effective than traditional natural cooling and air cooling. It is beneficial to protect the relevant components of the wire feeding system and ensure long-term stable wire feeding. It effectively avoids the safety of operators when changing wires, wire feeding nozzles and other parts, and will not cause high temperature burns. Attached Figure Description

[0021] Figure 1 This is an overall schematic diagram of the improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in this invention.

[0022] Figure 2 This is a schematic diagram of the assembly structure of the insulating pad and water-cooling bracket described in this invention.

[0023] Figure 3 This is a schematic diagram of the structure of the insulating pad described in this invention.

[0024] Figure 4 This is a side view of the improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in this invention.

[0025] Figure 5This is a cross-sectional structural diagram of the water-cooled support described in this invention. Detailed Implementation

[0026] 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.

[0027] like Figures 1-5 As shown, the improved water-cooled plasma spray gun system for simultaneous wire / powder spraying provided by the present invention includes: Plasma spray gun 100, powder feeding integrated device 110, insulating pad 120, water-cooled bracket 130 and water-cooled wire feeding device 170; The plasma spray gun 100 integrates a nozzle, an anode interface, a cathode interface, and a high-pressure mixed gas interface. An anode water cable connector 101 is provided at the far end of the anode interface, a cathode water cable connector 102 is provided at the far end of the cathode interface, and a high-pressure mixed gas connector is provided at the far end of the high-pressure mixed gas interface for connecting with an external high-pressure mixed gas.

[0028] In this embodiment, the plasma spray gun 100 is a CYS-1H plasma spray gun assembly.

[0029] A powder feeding integrated device 110 is provided at the nozzle of the plasma spray gun 100.

[0030] The insulating pad 120 is disposed on one side of the plasma spray gun 100, and the insulating pad 120 can move laterally relative to the plasma spray gun 100; the water-cooled bracket 130 is disposed on one side of the insulating pad 120 relative to the plasma spray gun 100, that is, the water-cooled bracket 130 and the plasma spray gun 100 are respectively disposed on both sides of the insulating pad 120, and the water-cooled bracket 130 can rotate relative to the insulating pad 120; the water-cooled wire feeding device 170 is detachably disposed at one end of the water-cooled bracket 130, and the water-cooled wire feeding device 170 can be selectively disposed opposite to the jet of the plasma spray gun 100.

[0031] In this embodiment, at least two first grooves 141 are provided at both ends of the insulating pad 120 to ensure the stability of the insulating pad 120. A first adjusting bolt 142 is provided in the first groove 141 to fix the insulating pad 120 on the plasma spray gun 100. The first adjusting bolt 142 can be slid or fixed in the first groove 141, so that the insulating pad 120 can move laterally relative to the plasma spray gun 100.

[0032] The water-cooled support 130 includes a fixing plate, a frame (not shown in the figure), a first water-cooling passage 133, a first water-cooling pipe quick-connect connector 131, and a second water-cooling pipe quick-connect connector 132. The fixing plate is rotatably disposed on one side of the insulating pad 120. The frame is integrally formed with the fixing plate, and the frame has a cavity structure. The first water-cooling passage 133 is disposed inside the frame and flows through the water-cooled wire feeding device 170. The first water-cooling pipe quick-connect connector 131 is disposed at the other end of the frame and is connected to one end of the first water-cooling passage 133. The second water-cooling pipe quick-connect connector 132 is disposed at the other end of the frame and is connected to the other end of the first water-cooling passage 133.

[0033] In this embodiment, the frame is fixed to one side of the insulating pad 120 by the second adjusting bolt 151. The water-cooled wire feeding device 170 is detachably passed through one end of the frame. The second adjusting bolt 151 is located at the middle of the other end of the frame away from the water-cooled wire feeding device 170. Two second sliding grooves 152 are symmetrically arranged on the fixing plate, and both second sliding grooves 152 are arc-shaped with the second adjusting bolt 151 as the center of the arc. A third adjusting bolt 153 is provided in the second sliding groove 152 for fixing the water-cooled bracket 130 to the insulating pad 120. The third adjusting bolt 153 can be selectively slid or fixed in the second sliding groove 152, so that the water-cooled bracket 130 can rotate relative to the insulating pad 120.

[0034] The fixing plate is located away from at least two first sliding grooves 141 and at least two first adjusting bolts 142, meaning that the positions of the second adjusting bolt 151, the second sliding groove 152 and the third adjusting bolt 153 do not interfere with the first sliding groove 141 and the first adjusting bolt 142, so that the insulating pad 120 and the water-cooling bracket can be adjusted simultaneously.

[0035] In another embodiment, there are three first slide grooves 141 arranged in a triangle, one of which is set with a fixed plate. In actual application, the first adjusting bolt 142 of this first slide groove 141 can be left untightened, and only the first adjusting bolts 142 of the other two first slide grooves 141 can be tightened to facilitate the adjustment of the insulating pad 120.

[0036] The plasma spray gun 100 is provided with a second water-cooling passage and a third water-cooling passage (not shown in the figure), both of which are used to cool the gun body. One end of the second water-cooling passage is connected to either the first water-cooling tube quick-connector 131 or the second water-cooling tube quick-connector 132 via a third water-cooling quick-connector 181, and the other end is connected to the anode water cable connector 101 of the plasma spray gun. One end of the third water-cooling passage can be selectively connected to either the first water-cooling tube quick-connector 131 or the second water-cooling tube quick-connector 132 via a fourth water-cooling quick-connector 182, and the other end is connected to the cathode water cable connector 102.

[0037] The anode water cable connector 101 is connected to the water outlet of the water chiller, the cathode water cable connector 102 is connected to the water inlet of the water chiller, and the third water-cooled quick connector 181 and the fourth water-cooled quick connector 182 are respectively connected to the first water-cooled pipe quick connector 131 or the second water-cooled pipe quick connector 132. That is, the first water-cooled pipe quick connector 131, the second water-cooled pipe quick connector 132 and the third water-cooled quick connector 181, the fourth water-cooled quick connector 182 are cross-connected by two external water pipes (not shown).

[0038] The frame is provided with a large anode connection threaded hole 160 for connecting to the large anode of the power supply.

[0039] In this embodiment, the insulating pad 120 is based on the nozzle end face of the plasma spray gun 100 and can move laterally by 1-20mm relative to the plasma spray gun 100; the water-cooled bracket 130 is based on being parallel to the nozzle of the plasma spray gun 100 and can rotate ±10° relative to the insulating pad 120.

[0040] The water-cooled wire feeding device 170 includes a water-cooled wire feeding head 171 and a fastening nut 172. The water-cooled wire feeding head 171 passes through a hole on one side of the frame and is then fixed by the fastening nut 172. The water-cooled wire feeding head 171 is connected to the wire feeding tube (which belongs to other external mechanisms). The water-cooled wire feeding head 171 and the water-cooled bracket 130 are sealed with two rubber rings.

[0041] The water circuit connection and working principle of the improved water-cooled plasma spray gun system for simultaneous wire / powder spraying described in this invention are as follows: The anode water cable connector of the plasma spray gun is connected to the outlet of the water chiller, serving as the cooling water inlet for the plasma spray gun system and the metal wire feeding device. After entering the plasma spray gun, the cooling water preferentially flows out from the third water-cooling quick-connect connector, then flows through the external water passage into the metal wire feeding device via either the first or second water-cooling quick-connect connector (no fixed connection method is specified here). This primarily cools the water-cooled wire feeding head. The water then flows out from either the second or first water-cooling quick-connect connector, and through the external water passage into the plasma spray gun via the fourth water-cooling quick-connect connector, thus cooling the gun body. Finally, the water flows out from the cathode water cable connector of the plasma spray gun (connected to the water chiller inlet) to complete the cooling water circulation.

[0042] The circuit connection and working principle of the improved water-cooled plasma spray gun system for simultaneous wire / powder spraying described in this invention are as follows: The anode water cable connector of the plasma spray gun is connected to the small power anode (referred to as the small anode), which together with the cathode inside the plasma spray gun forms the first working circuit. It is mainly used for the normal arc ignition and related work of the plasma spray gun. It should be noted that at this time, the plasma spray gun in the system has the same function and working principle as a regular plasma spray gun.

[0043] At the same time, the large anode connection threaded hole on the water-cooled bracket is connected to the large power anode (referred to as the large anode). At this time, all the metal parts on the water-cooled bracket (including the water-cooled wire feeder and the metal wire) are charged, so that the tip of the metal wire and the cathode in the plasma spray gun form a second working circuit, thereby melting the metal wire. It should be noted that the first working circuit always remains in working state during this process.

[0044] To ensure coating quality, the improved water-cooled plasma spray gun system for simultaneous wire / powder spraying described in this invention requires adjusting the position of the metal wire before spraying to ensure it remains in a suitable position within the plasma jet. The wire adjustment process includes two aspects: first, adjusting the distance between the wire and the nozzle end face along the jet axis; and second, adjusting the deflection angle between the wire and the jet along the jet cross-section. The specific adjustment process is as follows: First, loosen the first adjusting bolt. Adjust the insulating pad back and forth according to the needs of the spraying operation. When the distance between the metal wire and the nozzle end face meets the requirements, tighten the first adjusting bolt to fix the insulating pad to the plasma spray gun. Then, loosen the third adjusting bolt. Adjust the up and down rotation angle of the water-cooled bracket according to the needs of the spraying operation. When the angle between the metal wire and the nozzle orifice meets the requirements, tighten the third adjusting bolt to fix the water-cooled bracket to the insulating pad.

[0045] This invention presents an improved water-cooled plasma spray gun system for simultaneous wire / powder spraying. It optimizes the wire adjustment process, allowing operators to adjust the wire position more quickly and accurately, thus improving work efficiency. The overall system structure is also optimized, making the spraying system simpler and more efficient, facilitating future maintenance and upgrades. The highly efficient water cooling method is significantly more effective than traditional natural and air cooling, protecting components of the wire feeding system and ensuring stable wire feeding over long periods. This effectively prevents operator burns during wire and nozzle replacements.

[0046] 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. An improved water-cooled plasma spray gun system for simultaneous wire / powder spraying, characterized in that, include: Plasma spray gun; as well as An insulating pad is disposed on one side of the plasma spray gun, and the insulating pad is movable laterally relative to the plasma spray gun. A water-cooled bracket is disposed on one side of the insulating pad relative to the plasma spray gun, and the water-cooled bracket is rotatable relative to the insulating pad. A water-cooled wire feeding device is detachably mounted at one end of the water-cooled bracket, and the water-cooled wire feeding device can be selectively positioned opposite to the jet of the plasma spray gun. The lateral movement of the insulating pad and the rotation of the water-cooling bracket can be adjusted simultaneously.

2. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 1, characterized in that, Also includes: A powder feeding integrated device is installed at the nozzle of the plasma spray gun.

3. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 2, characterized in that, Also includes: At least two first grooves are respectively disposed at both ends of the insulating pad; At least two first adjusting bolts are disposed between the insulating pad and the plasma spray gun, and the at least two first adjusting bolts are respectively selectably slidable or fixed in at least two first grooves.

4. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 3, characterized in that, The water-cooling support includes: A fixing plate, which is rotatably disposed on one side of the insulating pad; The frame is integrated with the fixing plate, and the frame is a cavity structure; A first water-cooling passage is provided inside the frame and flows through the water-cooled wire feeding device. The first water-cooling pipe quick connector is located at the other end of the frame and is connected to one end of the first water-cooling passage. The second water-cooling pipe quick connector is located at the other end of the frame and is connected to the other end of the first water-cooling passage. The water-cooled wire feeding device passes through one end of the frame, and the fixing plate is away from at least two first sliding grooves and at least two first adjusting bolts.

5. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 4, characterized in that, The water-cooling support also includes: A large anode connection threaded hole is provided on the frame for connecting to the large anode of the power supply.

6. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 5, characterized in that, Also includes: The second water-cooling passage is located inside the plasma spray gun and is used to cool the gun body. The third water-cooling passage is located inside the plasma spray gun and is used to cool the gun body; The third water-cooling quick-connect connector is connected to one end of the second water-cooling passage. The fourth water-cooling quick-connect connector is connected to one end of the third water-cooling passage; The other end of the second water-cooling passage is connected to the anode water cable connector of the plasma spray gun, and the other end of the third water-cooling passage is connected to the cathode water cable connector.

7. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 6, characterized in that, The anode water cable connector is connected to the water outlet of the water chiller, the cathode water cable connector is connected to the water inlet of the water chiller, and the third and fourth water cooling quick connectors are respectively connected to the first or second water cooling pipe quick connector.

8. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 7, characterized in that, Also includes: The second adjusting bolt is fixed between the frame and the insulating pad; Two second sliding grooves are symmetrically arranged on both sides of one end of the fixed plate. Both second sliding grooves are arc-shaped and the center of the arc is the second adjusting bolt. Two third adjusting bolts are detachably fixed between the fixing plate and the insulating pad, and the two third adjusting bolts can be selectively slid or fixed in the two second sliding grooves respectively.

9. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 8, characterized in that, The insulating pad is referenced to the nozzle end face of the plasma spray gun and can be moved laterally by 1-20mm relative to the plasma spray gun.

10. The improved water-cooled plasma spray gun system for simultaneous wire / powder spraying as described in claim 9, characterized in that, The water-cooled bracket can rotate ±10° relative to the insulating pad, with the nozzle of the plasma spray gun as a reference.

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