An automatic cleaning and testing device for spray atomizers and spray gun air caps.

Abstract

This invention belongs to the field of automotive painting, specifically relating to an automatic cleaning and testing device for a spray atomizer and spray gun air cap. It includes a diaphragm pump, a pressure tank, a color-changing valve, a contoured docking component, a toilet-like device, and a water tank. The water tank outlet is connected to the diaphragm pump inlet, and the diaphragm pump outlet is connected to the pressure tank inlet. The color-changing valve has two inlet channels and one outlet channel. The pressure tank outlet is connected to one inlet channel of the color-changing valve, and the other inlet channel is connected to a compressed air pipeline. The one outlet channel of the color-changing valve is connected to the inlet of the contoured docking component. A toilet-like device is located below the contoured docking component, and its outlet is connected to the water tank inlet. The water tank, diaphragm pump, pressure tank, color-changing valve, and contoured docking component are connected by pipelines, and the toilet-like device and water tank are connected by pipelines. This invention connects the cleaning component to the contoured docking component, where the cleaning component is alternately rinsed by an aqueous solvent and compressed air, resulting in short cleaning time, low cost, and low energy consumption.

Description

Technical Field

[0001] This invention belongs to the field of automotive painting, specifically relating to an automatic cleaning and testing device for a spray atomizer and spray gun air cap. Background Technology

[0002] The atomizer cover of the spraying robot requires cleaning and maintenance of its forming air channels after approximately one week of continuous spraying. The original maintenance method involved disassembling the cover, immersing it in solvent, and using ultrasonic cleaning for at least 20 minutes. Afterward, the atomizer cover was removed, and manual cleaning of the holes was performed using 0.2mm and 0.1mm cleaning needles. Because the internal forming air channels of the atomizer cover are zigzag-shaped rather than straight, manual cleaning is difficult, taking approximately 2 hours to clean each cover. Furthermore, after cleaning, a uniform spray pattern test is required, necessitating the operation of the spray booth's circulating fan. The pass rate for the atomizer cover's spray pattern test is approximately 70%. Those failing require repeated manual cleaning and the above steps until all pass. Multiple tests result in prolonged operation of the spray booth's circulating fan, leading to energy waste and extended manual maintenance time.

[0003] The forming air of the spray gun, namely the atomized and fan-shaped air channels, also requires manual cleaning and dynamic and static spray tests, with the operation procedure similar to that of the atomizer cover. This can also lead to low test pass rates, resulting in prolonged operation of the spray booth's circulating fan, energy waste, and extended manual maintenance time. Summary of the Invention

[0004] To address the aforementioned problems in the existing technology, this invention provides an automatic cleaning and testing device for spray atomizers and spray gun air caps. The atomizer cover or spray gun air cap is connected to its corresponding contour docking part, and the forming air channel is rapidly and alternately flushed by water-based solvent and compressed air. The cleaning time is short, saving a lot of manpower maintenance costs and energy consumption, and improving the level of automation.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an automatic cleaning and testing device for a spray atomizer and spray gun air cap, comprising a diaphragm pump, a pressure tank, a color-changing valve, a contour docking component, a toilet device, and a water tank. The water tank outlet is connected to the diaphragm pump inlet, the diaphragm pump outlet is connected to the pressure tank inlet, the color-changing valve has two inlet channels and one outlet channel, the pressure tank outlet is connected to one inlet channel of the color-changing valve, the other inlet channel of the color-changing valve is connected to a compressed air pipeline, the one outlet channel of the color-changing valve is connected to the contour docking component inlet, a toilet device is disposed below the contour docking component, the toilet device outlet is connected to the water tank inlet, and the water tank, diaphragm pump, pressure tank, color-changing valve, and contour docking component are sequentially connected by pipelines, and the toilet device and water tank are connected by pipelines.

[0006] Furthermore, the diaphragm pump is equipped with a pressure gauge, a filter, and a manual pressure regulating valve, and the water tank is equipped with a feed port and a mechanical level gauge, with a low level setting at the bottom of the water tank.

[0007] Furthermore, the pressure tank is equipped with high and low liquid levels, and a pneumatic pressure regulating valve is installed at the inlet of the pressure tank.

[0008] Furthermore, the contoured docking part is connected to the cleaning part below. The cleaning part is set in the toilet device and a sealing ring is set at the connection between the toilet device and the cleaning part. The upper part of the toilet device is transparent and the lower part is equipped with a solvent tank. One end of the connecting rod structure is connected to the middle of the contoured docking part, and the other end of the connecting rod structure is fixed to the inner wall of the equipment.

[0009] Furthermore, a main air inlet is provided on the compressed air pipeline, which has two outputs. The compressed air pipeline output from the first branch of the main air inlet is equipped with an air filter and an air pressure regulating valve in sequence. The compressed air pipeline at the air pressure regulating valve also has two outputs. The compressed air pipeline output from the first branch of the air pressure regulating valve is connected to the other inlet channel of the color change valve, and the compressed air pipeline output from the second branch of the air pressure regulating valve is connected to the inlet of the pneumatic three-way valve. The outlet of the pneumatic three-way valve is connected to the pneumatic pressure regulating valve on the pressure tank. Four solenoid valves are connected to the compressed air pipeline output from the second branch of the main air inlet. The four solenoid valves are connected to the controllers of the two inlet channels of the diaphragm pump, the pneumatic three-way valve, and the color change valve, respectively, through the compressed air pipeline.

[0010] Furthermore, the contoured docking piece is equipped with three connectors, and the first outlet channel of the color-changing valve is connected to the three connectors respectively through three pipelines.

[0011] Compared with existing technologies, the advantages of this invention are as follows: This invention connects the atomizer housing or spray gun air cap to its corresponding contour-following docking component. The forming air channel is rapidly and alternately flushed by water-based solvent and compressed air, with the switching time freely set by a PLC. The flushing pressure is stable at approximately 7 kg, and the entire cleaning process takes about 5 minutes, or the cleaning time can be freely set according to actual conditions. The first-pass yield after cleaning is 100%, saving significant manpower maintenance costs and energy consumption, and improving automation levels. The toilet device of this invention has a sealing ring; the water-based solvent flushed out is collected and then returned to the pneumatic diaphragm pump, forming a closed loop. Furthermore, due to the sealing and ventilation treatment, VOC leakage is very small, minimizing the impact on the internal environment of the cleaning room. This invention is a flexible device; by changing the contour-following docking unit, it can switch between the atomizer housing and the spray gun air cap for automatic cleaning operations. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the present invention. Detailed Implementation

[0013] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0014] Figure 2 Solid lines indicate the passage of water-based solvents, dashed lines indicate the passage of compressed air, and bold solid lines indicate that compressed air and water-based solvents share a common pipeline.

[0015] Please see Figures 1 to 2 This invention provides the following technical solution: an automatic cleaning and testing device for a spray atomizer and spray gun air cap, comprising a diaphragm pump 1, a pressure tank 10, a color-changing valve 14, a contoured docking component 17, a toilet device 18, and a water tank 19. The water tank 19 is filled with an aqueous solvent. The outlet of the water tank 19 is connected to the inlet of the diaphragm pump 1, and the outlet of the diaphragm pump 1 is connected to the inlet of the pressure tank 10. The color-changing valve 14 has two inlet channels and one outlet channel. The outlet of the pressure tank 10 is connected to one inlet channel of the color-changing valve 14, and the other inlet channel of the color-changing valve 14 is connected to a compressed air pipeline. The one outlet channel of the color-changing valve 14 is connected to the inlet of the contoured docking component 17. A cleaning component is connected below the contoured docking component 17. In this embodiment, the cleaning component is an atomizer. The shape of the outer cover or spray gun air cap and the contoured docking part 17 can be customized as needed to make the contoured docking part 17 adaptable to various spray guns. A toilet device 18 is set below the contoured docking part 17. The cleaning part is pressed into the toilet device 18. The outlet of the toilet device 18 is connected to the inlet of the water tank 19. The water tank 19, diaphragm pump 1, pressure tank 10, color change valve 14, and contoured docking part 17 are connected in sequence by pipes. The toilet device 18 and the water tank 19 are connected by pipes. The flow path of the water-based solvent is in sequence: diaphragm pump 1, pressure tank 10, color change valve 14, contoured docking part 17, cleaning part, toilet device 18, and water tank 19. The flow path of the compressed air is in sequence: color change valve 14, contoured docking part 17, and cleaning part. The cleaning principle is as follows: the diaphragm pump 1 delivers water-based solvent to the pressure tank 10 through a pipeline. After being pressurized in the pressure tank 10, the water-based solvent is delivered to the first inlet channel of the color-changing valve 14 through a pipeline. The other inlet channel of the color-changing valve 14 is supplied with compressed air. The PLC settings enable the color-changing valve 14 to alternately deliver water-based solvent and compressed air from the first outlet channel to the inlet of the conformal docking part 17 through a pipeline, thereby alternately rinsing and cleaning the parts. The alternation time and the entire cleaning time are set by the PLC. The rinsing pressure of the compressed air is stabilized at seven kilograms. In this embodiment, the entire cleaning process takes about five minutes, with a first pass rate of 100%, saving a lot of manpower maintenance costs and energy consumption, and improving the level of automation.

[0016] Specifically, the diaphragm pump 1 is connected to a pressure gauge 2, a filter 3, and a manual pressure regulating valve 4. The water-based solvent coming out of the diaphragm pump 1 has its pressure adjusted by the manual pressure regulating valve 4 while the pressure gauge 2 is monitored to achieve a pressure stabilization effect. The water-based solvent is also filtered by the filter 3. After pressure stabilization and filtration, the water-based solvent is then transported to the pressure tank 10. The water tank 19 is equipped with a feed port 5 and a mechanical level gauge 6, and a low level 7 is set at the bottom of the water tank 19. The water-based solvent is added by reading the value of the mechanical level gauge 6 and referring to the low level 7. If it needs to be added, it is added through the feed port 5.

[0017] Specifically, the pressure tank 10 is equipped with high and low liquid levels 8. The high and low liquid levels 8 are set to monitor the amount of aqueous solvent in the pressure tank 10, thereby controlling the start and stop of the diaphragm pump 1. If the amount of aqueous solvent is detected to be at a low level, the diaphragm pump 1 is turned on; if the amount of aqueous solvent is detected to be at a high level, the diaphragm pump 1 is stopped. A pneumatic pressure regulating valve 9 is installed at the inlet of the pressure tank 10. The pneumatic pressure regulating valve 9 is connected to a compressed air pipeline, thereby directly pressurizing the aqueous solvent entering the pressure tank 10.

[0018] Specifically, the contoured docking part 17 is connected to the cleaning part below. The cleaning part is set in the toilet device 18, and a sealing ring is provided at the connection between the toilet device 18 and the cleaning part. The upper part of the toilet device 18 is transparent, and the lower part is equipped with a solvent tank. After the cleaning part below the contoured docking part 17 is rinsed, the water-based solvent rinsed out is collected in the solvent tank and then flows back to the diaphragm pump 1, forming a closed loop. Moreover, due to the sealing and ventilation treatment, the VOC leakage of this equipment is very small, and the impact on the internal environment of the gun washing room is small. The contoured docking part 17 is connected to one end of the connecting rod structure 16 in the middle. The other end of the connecting rod structure 16 is fixed to the inner side wall of the equipment. The contoured docking part 17 is fixed above the toilet device 18 through the connecting rod structure 16.

[0019] Specifically, the compressed air pipeline is equipped with a main air inlet 20, which branches into two compressed air pipelines. The first compressed air pipeline from the main air inlet 20 is equipped with an air filter 11 and an air pressure regulating valve 12. The air filter 11 and air pressure regulating valve 12 are used to stabilize and filter the air pressure, maintaining it at approximately seven kilograms. The compressed air pipeline at the air pressure regulating valve 12 also branches into two outlets. The first outlet of the air pressure regulating valve 12 connects to another inlet channel of the color-changing valve 14, and the second outlet connects to the inlet of a pneumatic three-way valve 13. The outlet of the pneumatic three-way valve 13 connects to the pneumatic pressure regulating valve 9 on the pressure tank 10 via the compressed air pipeline. The compressed air exits from the outlet of the pneumatic three-way valve 13 and is then transported through a compressed air pipeline to the pneumatic pressure regulating valve 9 on the pressure tank 10, thereby directly pressurizing the water-based solvent. Four solenoid valves 15 are connected to the compressed air pipeline of the second output of the main air inlet 20. The four solenoid valves 15 are connected through compressed air pipelines to the controllers of the two-position inlet channels of the diaphragm pump 1, the pneumatic three-way valve 13, and the color-changing valve 14, respectively. The functions of the four solenoid valves 15 are as follows: one solenoid valve 15 controls the start and stop of the diaphragm pump 1, one solenoid valve 15 controls the opening and closing of the pneumatic three-way valve 13, and the other two solenoid valves 15 control the opening and closing of the two-position inlet channels of the color-changing valve 14, respectively. The solenoid valves 15 themselves require compressed air to operate.

[0020] Specifically, the contoured docking part 17 is provided with three connectors 21, which is configured according to the structure of the atomizer cover in this embodiment. The atomizer cover is provided with two forming air channels and one cup washing channel. In this way, the three channels on the atomizer cover are independently connected to the three connectors on the contoured docking part 17. The first outlet channel of the color changing valve 14 is divided into three channels and connected to the three connectors 21 respectively through pipes. In this way, water-based solvent or compressed air is delivered to the three channels of the atomizer cover for rapid rinsing.

[0021] Specifically, the device has a detection function. A button box 22 and an electrical cabinet 23 are installed on the outer wall of the device. After the atomizer cover or air cap is installed with the corresponding contour docking part 17, the detection knob switch on the button box 22 is turned on. The PLC controls the color-changing valve 14 to open one of the water-based solvent channels. At this time, the state of the water-based solvent flowing out of each hole in the molding air channel and cup washing channel is judged by visual observation through the transparent toilet device 18 to confirm whether each molding air hole and cup washing hole has been cleaned.

[0022] The working principle of this invention is as follows: First, install the atomizer cover or air cap with the corresponding contour docking part 17. Then, set the alternation switching time of water-based solvent and compressed air, as well as the total cleaning process time, through the PLC. Turn on the cleaning button switch on the button box 22. Then, the PLC alternately controls the solenoid valves 15 connected to the controllers of the two inlet channels of the color-changing valve 14. Thus, the two solenoid valves 15 alternately control the two inlet channels of the color-changing valve 14 (one for pressurized water-based solvent and the other for 7 kg of compressed air), so that the pressurized water-based solvent and compressed air alternately clean the atomizer cover or air cap. The cleaning time is generally five minutes. After cleaning, turn on the detection knob switch on the button box 22. The PLC controls the color-changing valve 14 to open one channel for water-based solvent. At this time, visual observation is performed through the transparent toilet device 18 to judge the state of the water-based solvent flowing out of each hole in the forming air channel and the cup washing channel, and to confirm whether each forming air hole and cup washing hole has been cleaned.

[0023] During the cleaning process, if the pressure tank high and low level 8 on the pressure tank 10 detects that the amount of water-based solvent is at a low level, the diaphragm pump 1 will be turned on. At this time, the solenoid valve 15 controls the diaphragm pump 1 to open, and the diaphragm pump 1 delivers water-based solvent to the pressure tank 10. At the same time, the solenoid valve 15 controls the pneumatic three-way valve 13 to open, so that compressed air is delivered through the pipeline to the pneumatic pressure regulating valve 9 on the pressure tank 10, thereby directly pressurizing the water-based solvent. When the pressure tank high and low level 8 detects that the amount of water-based solvent is at a high level, the solenoid valve 15 controls the diaphragm pump 1 and the pneumatic three-way valve 13 to close.

[0024] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A spray atomizer and air cap automatic cleaning and testing apparatus characterized by, The device comprises a diaphragm pump (1), a pressure tank (10), a color changing valve (14), a profiled butt joint (17), a toilet device (18) and a water tank (19), the outlet of the water tank (19) is connected with the inlet of the diaphragm pump (1), the outlet of the diaphragm pump (1) is connected with the inlet of the pressure tank (10), the color changing valve (14) is provided with two inlets and one outlet, the outlet of the pressure tank (10) is connected with one of the inlets of the color changing valve (14), the other inlet of the color changing valve (14) is connected with a compressed air pipeline, one outlet of the color changing valve (14) is connected with the inlet of the profiled butt joint (17), the toilet device (18) is arranged below the profiled butt joint (17), the outlet of the toilet device (18) is connected with the inlet of the water tank (19), the water tank (19), the diaphragm pump (1), the pressure tank (10), the color changing valve (14) and the profiled butt joint (17) are connected in sequence through pipelines, and the toilet device (18) and the water tank (19) are connected through a pipeline.

2. A spray atomizer and air cap automatic cleaning and testing apparatus according to claim 1, wherein, A pressure gauge (2), a filter (3) and a manual pressure regulating valve (4) are connected to the diaphragm pump (1), a feeding opening (5) and a mechanical liquid level meter (6) are arranged on the water tank (19), and a low liquid level (7) is arranged at the bottom of the water tank (19).

3. A spray atomizer and air cap automatic cleaning and testing apparatus according to claim 2, wherein, A high and low liquid level (8) of the pressure tank (10) is arranged on the pressure tank (10), and a pneumatic pressure regulating valve (9) is arranged at the inlet of the pressure tank (10).

4. A spray atomizer and air cap automatic cleaning and testing apparatus according to claim 3, wherein, A cleaning part is connected below the profiled butt joint (17), the cleaning part is arranged in the toilet device (18), a sealing ring is arranged at the connection between the toilet device (18) and the cleaning part, the upper part of the toilet device (18) is transparent, a solvent tank is arranged at the lower part of the toilet device (18), one end of a connecting rod structure (16) is connected to the upper part of the profiled butt joint (17), and the other end of the connecting rod structure (16) is fixed to the inner side wall of the equipment.

5. A spray atomizer and air cap automatic cleaning and testing apparatus according to claim 4, wherein, A total air inlet (20) is arranged on the compressed air pipeline, the total air inlet (20) is divided into two paths, an air filter (11) and an air pressure regulating valve (12) are arranged in sequence on the compressed air pipeline of the first path of the total air inlet (20), the compressed air pipeline at the air pressure regulating valve (12) is divided into two paths, the compressed air pipeline of the first path of the air pressure regulating valve (12) is connected with the other inlet of the color changing valve (14), the compressed air pipeline of the second path of the air pressure regulating valve (12) is connected with the inlet of a pneumatic three-way valve (13), the outlet of the pneumatic three-way valve (13) is connected with the pneumatic pressure regulating valve (9) of the pressure tank (10), four electromagnetic valves (15) are connected with the compressed air pipeline of the second path of the total air inlet (20), and the four electromagnetic valves (15) are connected with the controllers of the diaphragm pump (1), the pneumatic three-way valve (13) and the two inlets of the color changing valve (14) through the compressed air pipeline respectively.

6. A spray atomizer and air cap automatic cleaning and testing apparatus according to claim 5, wherein, Three joints (21) are arranged on the upper part of the profiled butt joint (17), and one outlet of the color changing valve (14) is connected with the three joints (21) through pipelines in three paths.

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