Full-automatic tray spraying equipment

Abstract

The invention relates to full-automatic material tray spraying equipment which comprises a frame, one outer side of the frame is connected with a feeding trolley containing platform assembly, a tray taking and feeding mechanism is connected into the frame, and the feeding end of the tray taking and feeding mechanism is in butt joint with the discharging end of the feeding trolley containing platform assembly. The other outer side of the frame is connected with a discharging trolley placing platform assembly, a tray placing and discharging mechanism is connected into the frame, the discharging end of the tray placing and discharging mechanism is in butt joint with the feeding end of the discharging trolley placing platform assembly, and a tray spraying mechanism is connected into the portion, located between the tray taking and feeding mechanism and the tray placing and discharging mechanism, of the frame; the feeding end of the tray spraying mechanism is in butt joint with the discharging end of the tray taking and feeding mechanism, and the discharging end of the tray spraying mechanism is in butt joint with the feeding end of the tray placing and discharging mechanism.

Description

Technical Field

[0001] This invention relates to the field of industrial automation equipment technology, and to a fully automatic coating equipment for material trays, and more particularly to an automated coating equipment for surface treatment of cemented carbide bearings. Background Technology

[0002] In modern industrial fields such as powder metallurgy, the material tray serves as a critical load-bearing device, requiring repeated use in high-temperature or specific chemical environments. To prevent material from sticking to the tray, ensure smooth product demolding, and extend the tray's lifespan, a uniform insulating coating is typically applied to the cleaned tray surface. The thickness and uniformity of this coating directly affect the stability of product quality and production costs.

[0003] Traditional manual spraying mode

[0004] The operator holds a spray gun and sprays paint onto a tray placed on a simple fixture. This method relies heavily on the worker's experience and sense of responsibility, and has several inherent drawbacks.

[0005] Poor quality consistency: The spraying trajectory, moving speed, and spray gun distance are all based on feel, resulting in large fluctuations in coating thickness (usually far exceeding the tolerance of ±0.02mm), and uniformity cannot be guaranteed.

[0006] Harsh working conditions: The odor from the paint produced during the spraying process directly affects the health of operators and poses occupational safety hazards.

[0007] In view of the above-mentioned shortcomings, the designer actively researched and innovated in order to create a new type of fully automatic coating equipment with a material tray structure, which would make it more valuable for industrial use. Summary of the Invention

[0008] To solve the above-mentioned technical problems, the purpose of this invention is to provide a fully automatic coating equipment for material trays.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] An automatic tray spraying device includes a frame. A loading trolley placement platform assembly is connected to one outer side of the frame. A tray-retrieving and loading mechanism is connected inside the frame, with its inlet end connected to the outlet end of the loading trolley placement platform assembly. A unloading trolley placement platform assembly is connected to the other outer side of the frame. A tray-discharging mechanism is connected inside the frame, with its outlet end connected to the inlet end of the unloading trolley placement platform assembly. A tray spraying mechanism is connected inside the frame between the tray-retrieving and unloading mechanisms, with its inlet end connected to the outlet end of the tray-retrieving and unloading mechanisms, and its outlet end connected to the inlet end of the tray-discharging mechanism.

[0011] Preferably, in the fully automatic material tray spraying equipment, the loading cart placement platform assembly and the unloading cart placement platform assembly have the same structure and are arranged in a mirror-symmetric manner;

[0012] The loading trolley placement platform assembly includes a trolley platform frame, on which an L-shaped support rod is connected. One side of the L-shaped support rod is connected to a trolley limit adjustment plate for longitudinal positioning of the trolley, and the other side of the L-shaped support rod is connected to a trolley fixing cylinder and a trolley fixing knob for locking the trolley. When the trolley fixing knob is triggered, the cylinder rod of the trolley fixing cylinder is inserted into the fixing hole of the trolley. The cylinder rod and the trolley limit adjustment plate together clamp and fix the trolley.

[0013] Preferably, in the fully automatic coating equipment for material trays, the frame includes a frame, a touch screen bracket is connected to the frame, heavy-duty feet are connected to the bottom of the frame, and sheet metal door panels are installed on the frame.

[0014] Preferably, in the fully automatic coating equipment for material trays, the tray loading mechanism includes a tray loading lifting platform assembly, a tray loading horizontal conveying assembly, and a tray loading gripping assembly. The tray loading lifting platform assembly is connected to the tray loading horizontal conveying assembly, which is synchronously lifted and lowered thereon. The tray loading horizontal conveying assembly is connected to the tray loading gripping assembly for gripping products.

[0015] Preferably, in the fully automatic coating equipment for material trays, the tray-loading lifting platform assembly includes a Z-axis lifting module and four guide rails. The four guide rails are installed in two groups on both sides of the frame and are arranged opposite to each other. A tray-loading slider is slidably connected to the guide rails. The Z-axis lifting module is connected to the frame located between the two guide rails. A module slider connecting plate is connected to the tray-loading slider located at the Z-axis lifting module via a slider support connecting plate and a slider elevation plate. The Z-axis lifting module is connected to the module slider connecting plate via a sliding block. A slider connecting plate is connected to the tray-loading slider opposite to the Z-axis lifting module. A conveyor belt support connecting plate is connected between the slider connecting plate and the module slider connecting plate.

[0016] Preferably, in the fully automatic coating equipment for material trays, the tray loading horizontal conveyor assembly is a double-track conveyor belt driven by a tray loading drive motor. Both the double-track conveyor belt and the tray loading drive motor are mounted on the conveyor belt support connecting plate, and a tray limiting support plate is connected above the double-track conveyor belt.

[0017] Preferably, in the fully automatic material tray spraying equipment, the material feeding and gripping assembly includes a material pulling cylinder. The material pulling cylinder is connected to the material tray limiting support plate via a front cylinder support and a rear cylinder support. The piston rod of the material pulling cylinder is connected to a cylinder guide rail connecting block. Cylinder guide rail rods are connected to both sides of the cylinder guide rail connecting block. The cylinder guide rail rods pass through the cylinder guide rail flange connected to the front cylinder support. A material pulling movable claw with one-way folding is connected to the cylinder guide rail connecting block via a rotating shaft.

[0018] Preferably, the fully automatic tray spraying equipment includes a tray spraying mechanism comprising a feeding conveyor belt driven by a feeding drive motor, the feeding end of the feeding conveyor belt being connected to the discharge end of a double-track conveyor belt, a tray intercepting cylinder connected to the discharge end of the feeding conveyor belt, the drive shaft of the tray intercepting cylinder being connected to a tray blocking plate, a tray positioning micro switch connected to the feeding conveyor belt located at the tray intercepting cylinder, a tray lifting cylinder connected below the feeding conveyor belt, a tray lifting plate connected to the drive shaft of the tray lifting cylinder, a paint recovery component for preventing paint splashing connected within the frame, the paint recovery component being located above the tray lifting plate, a Y-axis spraying moving module connected within the frame, an X-axis spraying moving module connected to the Y-axis spraying moving module via a sliding block, a spray gun connecting rod connected to the X-axis spraying moving module via a sliding block, and a fixed spray gun connected to the spray gun connecting rod.

[0019] Preferably, in the fully automatic coating equipment with a material tray, the paint recovery component includes a paint receiving box located directly above the lifting material tray plate. The paint receiving box has a sheet metal structure with an oblique opening for accommodating and limiting the lifting material tray. A paint receiving cylinder is connected to the side of the paint receiving box, and the drive shaft of the paint receiving cylinder is connected to a paint receiving plate. During spraying, the paint receiving cylinder extends to form a semi-enclosed protective area between the paint receiving plate and the paint receiving box.

[0020] Preferably, in the fully automatic coating equipment for material trays, the tray unloading mechanism includes a tray unloading lifting platform assembly, a tray unloading horizontal conveying assembly, and a tray unloading pushing assembly. The tray unloading lifting platform assembly is connected to the tray unloading horizontal conveying assembly that is raised and lowered synchronously thereon. The tray unloading horizontal conveying assembly is connected to the tray unloading pushing assembly for pushing the product into the unloading cart placement platform assembly.

[0021] The unloading and palletizing lifting platform assembly and the pallet loading and unloading lifting platform assembly have the same structure, as do the unloading and palletizing horizontal conveyor assembly and the pallet loading horizontal conveyor assembly.

[0022] The tray unloading and pushing assembly includes two opposing clearance cylinders. The clearance cylinders are connected to the conveyor belt support connecting plate of the tray unloading and pushing assembly. The clearance cylinders are driven by the clearance connecting plate. The front end and rear end of the clearance connecting plate are respectively connected to a front support connecting plate and a rear support connecting plate. A pushing cylinder is connected between the front support connecting plate and the rear support connecting plate. Clearance holes are provided on the conveyor belt support connecting plate opposite to the pushing cylinder.

[0023] By means of the above-described solution, the present invention has at least the following advantages:

[0024] 1. This invention achieves seamless integration with standard multi-layer material carts in the factory area, completing the entire process of automatic transfer of material trays from full carts to empty carts, effectively improving work efficiency.

[0025] 2. This invention ensures that the functional coating formed on the surface of the material tray (e.g., 500mm*300mm) can be stably controlled within a specific range (e.g., 0.12-0.16mm) and that the uniformity error is small (±0.02mm).

[0026] 3. This invention eliminates the need for complex sensing end-effectors. It smoothly pulls the material tray out of the material cart layer without damage or jamming, without interfering with adjacent trays. Simultaneously, it ensures that the coated tray is completely and accurately pushed into the designated depth of the material cart layer, preventing tray stacking or slippage due to improper placement. It also prevents misalignment from scratching the freshly sprayed paint, thus avoiding impact on the product quality of the coated tray.

[0027] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0028] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the structure of the present invention;

[0030] Figure 2 yes Figure 1 Main view;

[0031] Figure 3 This is a schematic diagram of the framework of the present invention;

[0032] Figure 4 This is a schematic diagram of the structure of the loading vehicle placement platform assembly of the present invention;

[0033] Figure 5 yes Figure 4 Top view;

[0034] Figure 6 yes Figure 4 Side view;

[0035] Figure 7 This is a schematic diagram of the structure of the tray-loading mechanism of the present invention;

[0036] Figure 8 yes Figure 7 The main view;

[0037] Figure 9 yes Figure 7 Side view;

[0038] Figure 10 yes Figure 7 Top view;

[0039] Figure 11 This is a schematic diagram of the material tray spraying mechanism of the present invention;

[0040] Figure 12 yes Figure 11 The main view;

[0041] Figure 13 yes Figure 11 Side view;

[0042] Figure 14 This is a schematic diagram of the paint recycling component of the present invention;

[0043] Figure 15 This is a schematic diagram of the tray feeding mechanism of the present invention. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0046] Example

[0047] like Figures 1 to 15 As shown, a fully automatic tray spraying device includes a frame 6. A loading trolley placement platform assembly 1 is connected to one outer side of the frame 6. A tray picking and loading mechanism 2 is connected inside the frame 6. The inlet end of the tray picking and loading mechanism 2 is connected to the outlet end of the loading trolley placement platform assembly 1. A unloading trolley placement platform assembly 5 is connected to the other outer side of the frame 6. A tray unloading mechanism 4 is connected inside the frame 6. The outlet end of the tray unloading mechanism 4 is connected to the inlet end of the unloading trolley placement platform assembly 5. A tray spraying mechanism 3 is connected inside the frame 6 between the tray picking and loading mechanism 2 and the tray unloading mechanism 4. The inlet end of the tray spraying mechanism 3 is connected to the outlet end of the tray picking and loading mechanism 2, and the outlet end of the tray spraying mechanism 3 is connected to the inlet end of the tray unloading mechanism 4.

[0048] In this embodiment, the loading cart placement platform assembly 1 and the unloading cart placement platform assembly 5 have the same structure and are arranged in a mirror-symmetrical manner. The loading cart placement platform assembly 1 includes a cart platform frame 101, on which an L-shaped railing is connected. One side of the L-shaped railing is connected to a cart limit adjustment plate 107 for longitudinal positioning of the cart, and the other side of the L-shaped railing is connected to a cart fixing cylinder 103 and a cart fixing knob 104 for locking the cart. When the cart fixing knob 104 is triggered, the cylinder rod of the cart fixing cylinder 103 is inserted into the fixing hole of the cart.

[0049] Each platform integrates a material cart detection switch 102 (Omron E3ZG-D81) to detect the presence of the material cart. The extension and retraction status of the material cart fixing cylinder 103 is fed back in real time by its material cart origin detection switch 105 and material cart movement detection switch 106. In actual operation, the PLC only unlocks the fully automatic operation mode when the "material cart in position signal" (triggered by material cart detection switch 102) and the "material cart locked signal" (triggered by material cart movement detection switch 106) of the upper and lower material cart placement platforms are simultaneously satisfied, ensuring absolute safety in the operation.

[0050] In this embodiment, the frame 6 includes a rack 601, on which a touch screen bracket 602 is connected. Heavy-duty feet 603 are connected to the bottom of the rack 601, and a sheet metal door panel 604 is mounted on the rack 601. The rack 601 has a robust structure, and its loading and unloading areas are designed with rotational symmetry along a central axis for mounting all functional modules.

[0051] In this embodiment, the tray loading mechanism 2 includes a tray loading lifting platform assembly, a tray loading horizontal conveying assembly, and a tray loading gripping assembly. The tray loading lifting platform assembly is connected to the tray loading horizontal conveying assembly, which moves up and down synchronously thereon. The tray loading horizontal conveying assembly is connected to the tray loading gripping assembly for gripping products.

[0052] The pallet loading and unloading lifting platform assembly includes a Z-axis lifting module 201 (RXSB-210-1700 ball screw module, driven by a servo motor 205, Huichuan 750W, providing a maximum stroke of 1700mm, a load of 150kg, and a repeatability of ±0.03mm) and four guide rails 202. The four guide rails 202 are installed in two groups on both sides of the frame and are arranged opposite each other. A pallet loading slider 203 is slidably connected to each guide rail 202 and is located on the frame between two guide rails 202. The Z-axis lifting module 201 is connected to the plate-retrieving slider 203 located at the Z-axis lifting module 201. A module slider connecting plate 210 is connected to the slider 203 via a slider support connecting plate 204 and a slider elevation plate 209. The Z-axis lifting module 201 is connected to the module slider connecting plate 210 via a sliding block. A slider connecting plate 211 is connected to the plate-retrieving slider 203 opposite to the Z-axis lifting module 201. A conveyor belt support connecting plate 222 connects the slider connecting plate 211 and the module slider connecting plate 210. The Z-axis lifting module 201 is also equipped with an origin photoelectric switch 206, a lower limit photoelectric switch 207, and an upper limit photoelectric switch 208 for system zeroing and travel limit protection.

[0053] The horizontal conveyor assembly for picking up and loading the tray is a double-track conveyor belt 220 (SQR01-B445-L500) driven by a tray picking drive motor 221. Both the double-track conveyor belt 220 and the tray picking drive motor 221 are mounted on the conveyor belt support connecting plate 222. A tray limiting support plate 217 is connected above the double-track conveyor belt 220. The tray limiting support plate is 505mm wide to limit the 500mm wide tray and ensure centering.

[0054] The material handling and gripping assembly includes a material pulling cylinder 212, which is connected to the material tray limiting support plate 217 via a front cylinder support 215 and a rear cylinder support 216. The piston rod of the material pulling cylinder 212 is connected to a cylinder guide rail connecting block 223. Cylinder guide rail rods 224 are connected to both sides of the cylinder guide rail connecting block 223. The cylinder guide rail rods 224 pass through the cylinder guide rail flange 225 connected to the front cylinder support 215. A one-way folding material pulling claw 226 is connected to the cylinder guide rail connecting block 223 via a rotating shaft. The material pulling claw 226 is designed with a one-way folding structure. When the material pulling cylinder extends, the material pulling claw can fold upward and slide over the material tray; when the material pulling cylinder retracts, the material pulling claw is mechanically limited by the connecting block 223 and cannot fold, thereby hooking the edge of the material tray and pulling it out. The material pulling activity status is monitored by the material pulling origin detection switch 213 and the material pulling moving point detection switch 214.

[0055] Meanwhile, an Omron E3ZG-D82 (no tray) detection switch and an Omron E3ZG-D81 (tray arrival detection switch) are installed in the area of ​​the tray-loading and gripping component. The tray absence detection switch 218 is used to detect whether there is a tray on the current layer of the material cart when the lifting platform moves layer by layer, and decide whether to perform the tray retrieval action; the tray arrival detection switch 219 is used to confirm that the tray has been successfully pulled to the designated position on the conveyor belt.

[0056] In this embodiment, the material tray spraying mechanism 3 includes a feeding conveyor belt 301 (SQP01-B445-L620) driven by a feeding drive motor 302 (precision motor). The feeding end of the feeding conveyor belt 301 is connected to the discharge end of the double-track conveyor belt 220. A material tray intercepting cylinder 303 (TR20X40S) is connected to the discharge end of the feeding conveyor belt 301. The drive shaft of the material tray intercepting cylinder 303 is connected to a material tray blocking plate 307. A material tray positioning micro switch 306 is connected to the feeding conveyor belt 301 located at the material tray intercepting cylinder 303. A material tray lifting cylinder 308 is connected below the feeding conveyor belt 301. A lifting plate 325 is connected to the drive shaft of the material tray lifting cylinder 308.

[0057] Interception and Sensing: The tray interception cylinder 303 (TR20X40S) is initially in the extended state, with a tray blocking plate 307 and a tray positioning micro switch 306 (Omron Z-15GL-B) mounted on it. The tray impacts the blocking plate 307, triggering the interception micro switch 306 to achieve precise positioning detection. The status of the tray interception cylinder is fed back by the interception origin detection switch 304 and the interception moving point detection switch 305.

[0058] Lifting and Transfer: The material tray lifting cylinder 308 (Airtac TCL32X80S) activates upon receiving a positioning signal, lifting the material tray via the lifting plate 325. Its status is monitored by the lifting origin detection switch 309 and the lifting moving point detection switch 310 of the lifting cylinder.

[0059] The frame 6 is connected to a paint recovery assembly for preventing paint splashing. The paint recovery assembly is located above the lifting tray plate 325. The frame 6 is connected to a Y-axis spraying moving module. The Y-axis spraying moving module is connected to an X-axis spraying moving module via a sliding block. The X-axis spraying moving module is connected to a spray gun connecting rod 322 via a sliding block. A fixed spray gun 323 is connected to the spray gun connecting rod 322.

[0060] The Y-axis painting moving module includes a painting Y-axis module 318 (RXT80-750), which is horizontally mounted on a frame. To enhance its motion stability, an HGR30 guide rail 328 is mounted parallel to its side, on which a painting slider 329 (HGH30CA) is mounted. The Y-axis slider on the painting Y-axis module 318 and the painting slider 329 are rigidly connected through a Y-axis slider connecting base 330, forming a stable long-stroke (750mm) motion pair. The painting Y-axis module 318 is driven by a Y-axis servo motor 333.

[0061] The X-axis spraying moving module includes a spraying X-axis module 314 (RXT50-300), which is vertically mounted on the Y-axis slider connecting base 330 via an X-axis base connecting plate 331 and is driven by an X-axis servo motor 332.

[0062] The spray gun connecting rod 322 is mounted on the X-axis slider, and the spray gun 323 (Rongchen WA-200) is fixed at its end. The spray gun can perform interpolation movements with high repeatability (±0.01mm) in the XY plane.

[0063] Spraying positioning and protection: The X-axis is equipped with an X-axis origin photoelectric switch 315, an X-axis lower limit switch 316, and an X-axis upper limit switch 317 for spraying the X-axis; the Y-axis is equipped with a Y-axis origin photoelectric switch 319, a Y-axis lower limit switch 320, and a Y-axis upper limit switch 321 for spraying the Y-axis.

[0064] Meanwhile, the material tray limit bars 324 are installed on both sides of the feeding conveyor belt 301 to restrict the movement of the material tray in the width direction.

[0065] The paint recycling assembly includes a paint receiving box 327, which is located directly above the lifting tray plate 325. The paint receiving box 327 has a sheet metal structure with an oblique opening to accommodate and limit the lifting tray. A paint receiving cylinder 311 is connected to the side of the paint receiving box 327. The drive shaft of the paint receiving cylinder 311 is connected to a paint receiving plate 326. During spraying, the paint receiving cylinder 311 extends so that the paint receiving plate 326 and the paint receiving box form a semi-enclosed protective area.

[0066] Fixed containment: The paint box 327 is located above the lifting station and is a sheet metal structure with an angled opening, used to contain and limit the lifted material tray.

[0067] Active protection: The paint receiving cylinder 311 (Airtac TR25X50S) drives the paint receiving plate 326. During spraying, the paint receiving cylinder extends to form a semi-enclosed protective zone between the paint receiving plate and the paint receiving box. The cylinder status is fed back by the paint origin detection switch 312 and the paint movement detection switch 313 of the paint receiving cylinder.

[0068] In an embodiment, the tray unloading mechanism 4 includes a tray unloading lifting platform assembly, a tray unloading horizontal conveying assembly, and a tray unloading pushing assembly. The tray unloading lifting platform assembly is connected to the tray unloading horizontal conveying assembly that is raised and lowered synchronously thereon. The tray unloading horizontal conveying assembly is connected to the tray unloading pushing assembly for pushing the product into the unloading cart placement platform assembly.

[0069] The pallet unloading lifting platform assembly and the pallet loading lifting platform assembly have the same structure. During installation, their positions are symmetrically arranged. The pallet unloading horizontal conveyor assembly and the pallet loading horizontal conveyor assembly have the same structure. The specific structures of the pallet unloading lifting platform assembly and the pallet unloading horizontal conveyor assembly will not be described in detail.

[0070] The tray unloading and pushing assembly includes two opposing clearance cylinders 401. The clearance cylinders 401 are connected to the conveyor belt support connecting plate of the tray unloading and pushing assembly. The clearance cylinders 401 are driven by a clearance connecting plate 402. The front end and rear end of the clearance connecting plate 402 are respectively connected to a front support connecting plate 403 and a rear support connecting plate 404. A pushing cylinder 405 is connected between the front support connecting plate 403 and the rear support connecting plate 404. A clearance hole is provided on the conveyor belt support connecting plate opposite to the pushing cylinder 405.

[0071] The clearance cylinder (Airtac TCL25X30S) is mounted on the tray limit support plate, and its piston rod is connected to the front support connecting plate and the rear support connecting plate through the clearance cylinder connecting plate. The push-in cylinder (Airtac MA16X175SCA) is mounted on this support base, and the up and down movement of the push-in cylinder is controlled by the clearance cylinder. The status of the clearance cylinder is monitored by the clearance origin detection switch and the clearance moving point detection switch for up and down clearance.

[0072] Push-in execution: Push-in cylinder (used to push the material tray completely into the depth of the material cart, its status is monitored by the push-in origin detection switch and the push-in moving point detection switch).

[0073] The tray feeding mechanism is equipped with a tray presence detection switch and a tray arrival detection switch, which have the same functions as the tray loading mechanism 2, and will not be described in detail here.

[0074] Specific workflow: In the initial state, the avoidance cylinder extends, causing the pusher cylinder to rise and clear the space for the material tray to move. When the material tray is fed into the material car layer by the conveyor belt of the tray unloading mechanism but has not yet fully entered the layer, the avoidance cylinder retracts first, causing the entire pusher cylinder to descend, so that the pusher rod is directly in front of the center of the material tray. Subsequently, the pusher cylinder extends, pushing the material tray completely into the depth of the material car layer. After completion, the pusher cylinder retracts, and the avoidance cylinder extends to reset.

[0075] The control of this invention is implemented by a programmable logic controller (PLC). This PLC collects all detection switch signals (a total of 45, including photoelectric switches, proximity switches, and micro switches) throughout the equipment via its input module, and controls the drivers of all servo motors, stepper / precision motors, and the solenoid valves of each cylinder via its output module. According to the preset program logic, the PLC processes sensor information in real time, precisely scheduling the sequence and rhythm of mechanical actions, achieving fully automated and intelligent operation from "double-cart safety confirmation" to "completion of batch painting and automatic shutdown alarm."

[0076] 1. Preparation and Power-on Phase

[0077] The operator transports the fully loaded trolley, which has been cleaned and filled with 80 pallets, to the loading platform using a workshop-standard trolley transfer cart. The trolley is then pushed onto the platform frame, ensuring its side is flush against the trolley limit adjustment plate for positioning. Subsequently, the operator moves the trolley fixing knob on the platform, triggering the extension of the trolley fixing cylinder. The piston rod inserts into the corresponding hole at the bottom of the trolley, mechanically locking it. At this time, the cylinder's moving point detection switch is triggered, sending a "locked" signal. Simultaneously, the trolley detection switch (102) installed on the platform detects the metal trolley and sends a "trolley in position" signal.

[0078] At the same time, an empty material cart is placed and locked onto the unloading cart platform in the same manner. The material cart detection switch and the material cart fixing cylinder moving point detection switch on it also send corresponding "in position" and "locked" signals.

[0079] When the equipment is powered on, the PLC system performs a self-test. The "Automatic Mode Start" button on the touchscreen is activated only when the PLC's input module simultaneously receives a total of four key signals from the loading and unloading platforms.

[0080] 2. Automatic startup and initialization

[0081] The operator presses the "Automatic Start" button. The equipment first performs an initialization reset: the tray interception cylinder in the spraying area remains extended, while the paint receiving cylinder and tray lifting cylinder are retracted; the X and Y axes of the spray gun return to their mechanical origins. The loading / unloading Z-axis of the tray loading and unloading areas respectively drives their composite lifting platforms to their respective "standby positions" (usually the highest position in the loading area and the lowest position in the unloading area). The double-rail conveyor belt in the tray unloading area is adjusted to be at the same height as the feeding conveyor belt in the spraying area, positioned at the tray receiving waiting position, awaiting the receipt of the first tray that has been sprayed.

[0082] 3. Cyclic operation process (the cycle is based on the complete processing of one material tray).

[0083] The working principle of this invention is as follows:

[0084] Step 1: Loading and Removing Trays

[0085] The pallet-loading mechanism in the loading area descends, first moving to the "detection position" at the top of the material cart. This position is calculated by the program based on the height of the material cart, ensuring that the probe of the pallet detection switch is aligned with the height of the pallet.

[0086] Detection and judgment: The presence or absence of a material tray is detected by the switch of the current layer. If a material tray is detected (metal sensing), the next step is executed; if there is no material tray, the Z-axis lifting module 201 descends by one layer height and continues to detect the next layer until a layer with a material tray is found.

[0087] Precise positioning: After confirming the presence of a tray, the Z-axis lifting module 201 moves to the "tray retrieval position". This position ensures that the plane of the material cart layer where the tray is located is precisely flush with the plane of the dual-track conveyor belt in the loading area, forming a seamless transition.

[0088] Execute disk fetch:

[0089] When the material-pulling cylinder is energized, it extends. When the material-pulling movable claw at the front end moves forward, it encounters resistance and folds upward upon contact with the edge of the material tray, thus sliding over the upper surface of the material tray.

[0090] After the cylinder extends its full 400mm stroke, there is no obstruction in front of the material pulling claw, which naturally droops under gravity. At this point, the material pulling point detection switch is triggered.

[0091] When the material pulling cylinder retracts in the opposite direction, the back of the material pulling claw is rigidly limited by the cylinder guide rail connecting block, preventing it from folding upwards and thus hooking onto the subsequent edge of the material tray.

[0092] The cylinder retracts fully, smoothly pulling the material tray out of the material cart layer and placing it on the double-track conveyor belt in the loading area. The material pulling origin detection switch is triggered, confirming that the tray removal operation is complete.

[0093] Conveying and Waiting: When the tray arrival detection switch senses the tray, the conveyor belt in the loading area starts, conveying the tray a fixed distance towards the spraying area and stopping at the "spraying standby position". The Z-axis lifting module moves to the tray conveying position, adjusting the plane of the dual-rail conveyor belt to be at the same height as the feeding conveyor belt plane in the spraying area. At this time, the tray loading area has completed the preparation of one tray.

[0094] Step 2: Spraying operations (can be carried out in parallel with the next step of loading and unloading materials).

[0095] Feeding and Positioning: If the spraying area is idle (i.e., the previous tray has been processed and sent out), the feeding conveyor belt of the spraying area and the loading conveyor belt start synchronously, sending the tray in the "standby position" into the spraying area. During the movement, the tray hits the tray blocking plate in the extended state, thereby triggering the tray positioning micro switch installed on it, and the conveyor belt stops immediately.

[0096] Lifting and closing:

[0097] The material tray lifting cylinder extends and lifts the material tray vertically through the lifting plate, so that it is completely inserted into the paint receiving box at the upper slant opening. The lifting cylinder moving point detection switch is triggered.

[0098] The paint receiving cylinder extends synchronously, pushing the paint receiving plate to move below the material tray, forming a three-sided splash-proof space together with the paint receiving box. The paint receiving cylinder movement point detection switch is triggered.

[0099] The material tray intercepting cylinder retracts, and the blocking plate on it leaves the material tray conveying path to make way for subsequent material trays to enter and exit. The intercepting cylinder origin detection switch is triggered.

[0100] Spraying execution: After all preparatory actions are completed and feedback signals are sent to the PLC, the paint valve of the spray gun opens. The servo motor drives the spraying Y-axis moving module, causing the entire spray gun assembly to move at a constant speed along the length of the material tray (750mm stroke), spraying one side of the material tray area; after reaching the endpoint, the servo motor drives the spraying X-axis module to move one set step distance; then the Y-axis moves in the opposite direction, spraying the adjacent area. Through precise interpolation movements of the X and Y axes, the spray gun covers the entire 500mm×300mm material tray working surface with a constant speed and equidistant scanning path, ensuring that the coating thickness uniformity is within ±0.02mm.

[0101] Descent and Sending:

[0102] After spraying is completed, the spray gun is shut off. The paint receiving cylinder retracts first, the paint receiving plate is moved away, and its origin detection switch is triggered.

[0103] The material tray lifting cylinder retracts, lowering the coated material tray back onto the feeding conveyor belt. Its origin detection switch is then triggered.

[0104] The feeding conveyor belt and the unloading area conveyor belt, which have been moved to the docking height in advance, start synchronously to transport the material tray to the unloading area.

[0105] After the tray leaves, the tray intercepting cylinder extends and resets, ready to intercept the next tray of paint to be sprayed.

[0106] Step 3: Loading and Placing Materials onto Trays

[0107] Receiving and Positioning: When the material tray arrival detection switch in the unloading area senses that the material tray has been fed in, the conveyor belt stops. At the same time, the Z-axis lifting module 201 in the unloading area calculates according to the program and moves its composite lifting platform to the current "lowest empty layer" height of the empty material cart, and makes the conveyor belt plane flush with the support surface of the material tray at that layer.

[0108] Execute disk release:

[0109] Detection and Judgment: The presence or absence of a material tray detection switch 218 in the material unloading area is used to confirm whether the material cart layer is empty (there should be no material tray signal). This is a preventive detection.

[0110] Push-in into position: Because the material tray fed by the conveyor belt may not have fully entered the deepest part of the material cart slot, the tray release mechanism is activated:

[0111] i. The avoidance cylinder retracts, and the entire push cylinder is lowered by the avoidance cylinder connecting plate, so that the initial position of the push rod is lower than the upper surface of the material tray, thus completing the avoidance.

[0112] ii. The cylinder extends, and its push rod moves forward horizontally, pushing the material tray completely into the predetermined position of the material cart layer, triggering the pusher movement detection switch.

[0113] iii. The push-in cylinder retracts, and then the avoidance cylinder extends and resets.

[0114] Hierarchical update:

[0115] After completing the placement of the tray for this layer, the Z-axis lifting module 201 in the unloading area returns to the receiving tray waiting position to await the next tray that has been coated. It is ready to receive and place the next tray, and the next feeding will raise it by one standard layer height. At the same time, after completing the tray retrieval, the Z-axis lifting module 201 in the loading area descends to the next tray waiting layer (or continues to perform detection) and sends the new tray to the "coating standby position" to wait for the coating area to become idle again.

[0116] Step 4: End of loop

[0117] The above-mentioned "tray picking-spraying-tray placement" cycle is performed automatically and continuously. The Z-axis lifting module 201 in the tray picking and loading area descends layer by layer from the top of the material cart to pick up the trays; the Z-axis lifting module 201 in the tray placement and unloading area rises layer by layer from the bottom of the material cart to place the trays.

[0118] When the material tray detection switch in the loading area continuously detects an empty layer state for a preset number of times (e.g., corresponding to 80 layers), or when the program counter confirms that 80 trays have been processed, the PLC determines that the loading car is empty and the unloading car is full.

[0119] The equipment immediately stops all cyclic operations, and all moving parts return to their safe positions. Simultaneously, the equipment triggers an audible and visual alarm (such as a ringing bell and flashing indicator lights) to notify the operator that the current batch spraying operation has been completed. The operator can then loosen the fixing knob, remove the fully loaded spraying material cart and the empty material cart, and prepare for the next work cycle.

[0120] This invention achieves seamless integration with standard multi-layer material carts in the factory, completing the fully automated transfer of material trays from full to empty carts, effectively improving work efficiency. It ensures a functional coating is formed on the surface of the material trays (e.g., 500mm*300mm), ensuring the coating thickness is stably controlled within a specific range (e.g., 0.12-0.16mm) with minimal uniformity error (±0.02mm). It eliminates the need for complex sensing end-effectors. The material trays are smoothly pulled out of the cart layers without damage or jamming, without interfering with adjacent trays. Simultaneously, it ensures the coated trays are completely and accurately pushed into the designated depth of the cart layer, preventing stacking or slippage due to improper placement. It also prevents scratches on freshly sprayed paint caused by misalignment, thus protecting the product quality of the coated trays.

Claims

1. A fully automatic tray-based spraying equipment, characterized in that: The system includes a frame (6), an outer side of which is connected to a loading cart placement platform assembly (1), a tray loading mechanism (2) is connected inside the frame (6), the inlet end of the tray loading mechanism (2) is connected to the outlet end of the loading cart placement platform assembly (1), the other outer side of the frame (6) is connected to a unloading cart placement platform assembly (5), a tray unloading mechanism (4) is connected inside the frame (6), the outlet end of the tray unloading mechanism (4) is connected to the inlet end of the unloading cart placement platform assembly (5), and a tray spraying mechanism (3) is connected inside the frame (6) between the tray loading mechanism (2) and the tray unloading mechanism (4), the inlet end of the tray spraying mechanism (3) is connected to the outlet end of the tray loading mechanism (2) and the outlet end of the tray spraying mechanism (3) is connected to the inlet end of the tray unloading mechanism (4).

2. The fully automatic tray spraying equipment according to claim 1, characterized in that: The loading platform assembly (1) and the unloading platform assembly (5) have the same structure; The loading platform assembly (1) includes a loading platform frame (101), an L-shaped railing is connected to the loading platform frame (101), a loading limit adjustment plate (107) for longitudinal positioning of the loading vehicle is connected to one side of the L-shaped railing, and a loading vehicle fixing cylinder (103) and a loading vehicle fixing knob (104) for locking the loading vehicle are connected to the other side of the L-shaped railing. By triggering the loading vehicle fixing knob (104), the cylinder rod of the loading vehicle fixing cylinder (103) is inserted into the fixing hole of the loading vehicle.

3. The fully automatic tray spraying equipment according to claim 1, characterized in that: The frame (6) includes a frame (601), a touch screen bracket (602) is connected to the frame (601), a heavy-duty foot (603) is connected to the bottom of the frame (601), and a sheet metal door panel (604) is installed on the frame (601).

4. The fully automatic tray spraying equipment according to claim 1, characterized in that: The tray loading mechanism (2) includes a tray loading lifting platform assembly, a tray loading horizontal conveying assembly, and a tray loading gripping assembly. The tray loading lifting platform assembly is connected to the tray loading horizontal conveying assembly which is lifted and lowered synchronously on it. The tray loading horizontal conveying assembly is connected to the tray loading gripping assembly for gripping products.

5. The fully automatic tray spraying equipment according to claim 4, characterized in that: The pallet loading and unloading lifting platform assembly includes a Z-axis lifting module (201) and four guide rails (202). The four guide rails (202) are installed in two groups on both sides of the frame and are arranged opposite to each other. A pallet loading slider (203) is slidably connected to the guide rail (202). The Z-axis lifting module (201) is connected to the frame between the two guide rails (202). The pallet loading slider (203) located at the Z-axis lifting module (201) is connected to a module slider connecting plate (210) through a slider support connecting plate (204) and a slider raising plate (209). The Z-axis lifting module (201) is connected to the module slider connecting plate (210) through a sliding block. A slider connecting plate (211) is connected to the pallet loading slider (203) opposite to the Z-axis lifting module (201). A conveyor belt support connecting plate (222) is connected between the slider connecting plate (211) and the module slider connecting plate (210).

6. The fully automatic tray spraying equipment according to claim 4, characterized in that: The horizontal conveyor assembly for picking up and feeding the tray is a double-track conveyor belt (220) driven by a tray picking drive motor (221). Both the double-track conveyor belt (220) and the tray picking drive motor (221) are mounted on the conveyor belt support connecting plate (222). A tray limiting support plate (217) is connected above the double-track conveyor belt (220).

7. The fully automatic tray spraying equipment according to claim 4, characterized in that: The pallet feeding and gripping assembly includes a material pulling cylinder (212). The material pulling cylinder (212) is connected to the pallet limiting support plate (217) via a front cylinder support (215) and a rear cylinder support (216). The piston rod of the material pulling cylinder (212) is connected to a cylinder guide rail connecting block (223). Cylinder guide rail rods (224) are connected to both sides of the cylinder guide rail connecting block (223). The cylinder guide rail rods (224) pass through the cylinder guide rail flange (225) connected to the front cylinder support (215). A material pulling movable claw (226) with one-way folding is connected to the cylinder guide rail connecting block (223) via a rotating shaft.

8. The fully automatic tray spraying equipment according to claim 1, characterized in that: The material tray spraying mechanism (3) includes a feeding conveyor belt (301) driven by a feeding drive motor (302). The feeding end of the feeding conveyor belt (301) is connected to the discharge end of the double-track conveyor belt (220). A material tray intercepting cylinder (303) is connected to the discharge end of the feeding conveyor belt (301). The drive shaft of the material tray intercepting cylinder (303) is connected to the material tray blocking plate (307). A material tray positioning micro switch (306) is connected to the feeding conveyor belt (301) located at the material tray intercepting cylinder (303). A material tray lifting cylinder (308) is connected below, and a lifting material tray plate (325) is connected to the drive shaft of the material tray lifting cylinder (308). A paint recycling component for preventing paint splashing is connected inside the frame (6). The paint recycling component is located above the lifting material tray plate (325). A Y-axis spraying moving module is connected inside the frame (6). An X-axis spraying moving module is connected to the Y-axis spraying moving module through a sliding block. A spray gun connecting rod (322) is connected to the X-axis spraying moving module through a sliding block. A fixed spray gun (323) is connected to the spray gun connecting rod (322).

9. The fully automatic tray spraying equipment according to claim 8, characterized in that: The paint recycling assembly includes a paint receiving box (327), which is located directly above the lifting tray plate (325). The paint receiving box (327) has a sheet metal structure with an oblique opening to accommodate and limit the lifting tray. A paint receiving cylinder (311) is connected to the side of the paint receiving box (327). The drive shaft of the paint receiving cylinder (311) is connected to a paint receiving plate (326). During spraying, the paint receiving cylinder (311) extends to form a semi-enclosed protective area between the paint receiving plate (326) and the paint receiving box.

10. The fully automatic tray spraying equipment according to claim 1, characterized in that: The tray unloading mechanism (4) includes a tray unloading lifting platform assembly, a tray unloading horizontal conveying assembly, and a tray unloading pushing assembly. The tray unloading lifting platform assembly is connected to a tray unloading horizontal conveying assembly that is raised and lowered synchronously on it. The tray unloading horizontal conveying assembly is connected to a tray unloading pushing assembly for pushing the product into the unloading cart placement platform assembly. The unloading and palletizing lifting platform assembly and the pallet loading and unloading lifting platform assembly have the same structure, as do the unloading and palletizing horizontal conveyor assembly and the pallet loading horizontal conveyor assembly. The tray unloading and pushing assembly includes two opposing avoidance cylinders (401). The avoidance cylinders (401) are connected to the conveyor belt support connecting plate of the tray unloading and pushing assembly. The avoidance cylinders (401) are driven by an avoidance connecting plate (402). The front end and rear end of the avoidance connecting plate (402) are respectively connected to a front support connecting plate (403) and a rear support connecting plate (404). A pushing cylinder (405) is connected between the front support connecting plate (403) and the rear support connecting plate (404). An avoidance hole is provided on the conveyor belt support connecting plate opposite to the pushing cylinder (405).

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