Self-adaptive temperature control plasma spraying device
The adaptive temperature-controlled plasma spraying device uses a six-axis robotic arm and infrared sensors to dynamically adjust the temperature, solving the problems of uneven coating and thermal deformation caused by temperature fluctuations in traditional plasma spraying devices, thus improving coating quality and production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- FOSHAN KANGTAIWEI NEW MATERIAL CO LTD
- Filing Date
- 2025-05-20
- Publication Date
- 2026-04-24
AI Technical Summary
Traditional plasma spraying equipment lacks dynamic temperature control, resulting in significant temperature fluctuations on the substrate surface. This leads to uneven coating thickness and insufficient adhesion, which may cause thermal deformation and processing failure, especially for thin-walled parts or heat-sensitive materials.
The plasma spraying device, which adopts adaptive temperature control, carries the plasma spray gun through a six-axis robotic arm. Combined with an infrared thermal imaging sensor and a PID controller, it scans the temperature in real time and dynamically adjusts the cooling intensity and spraying path. The cooling component and the dust collection component work together to ensure accurate temperature control and coating quality.
This improved the uniformity and bonding strength of the coating, prevented thermal deformation of the workpiece, and increased the coating qualification rate and production efficiency.
Smart Images
Figure CN224160669U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of plasma spraying equipment technology, and in particular to a plasma spraying device with adaptive temperature control. Background Technology
[0002] Plasma spraying equipment is a device that uses a plasma arc as a heat source to heat powdered or filamentous coating materials to a molten or semi-molten state and spray them at high speed onto a pre-treated substrate surface to form a coating with specific properties. It is widely used in aerospace, machinery manufacturing, automotive industry and other fields.
[0003] However, traditional plasma spraying fixtures usually lack dynamic temperature control. During the spraying process, the temperature of the substrate surface fluctuates significantly, which can easily lead to problems such as uneven coating thickness and insufficient adhesion. If the local temperature is too high during spraying, the workpiece is prone to thermal deformation. Especially for thin-walled parts or heat-sensitive materials, this deformation may directly affect its dimensional accuracy and structural strength, which may lead to a decrease in the coating qualification rate or even cause processing failure.
[0004] For example, when plasma spraying high-temperature ceramic coatings onto thin-walled turbine blades in aero engines, the local temperature during the spraying process of traditional spraying equipment exceeds the tolerance range of the blade substrate (nickel-based high-temperature alloy), which may cause local softening of the substrate. The bonding strength between the coating and the blade is lower than the design requirements, and it is easy to peel off under high stress. Utility Model Content
[0005] This utility model discloses an adaptive temperature control plasma spraying device, which aims to solve the problem that traditional plasma spraying tooling usually lacks dynamic temperature control function. During the spraying process, the surface temperature of the substrate fluctuates significantly, which can easily lead to problems such as uneven coating thickness and insufficient adhesion. If the local temperature is too high during spraying, the workpiece is prone to thermal deformation. Especially for thin-walled parts or heat-sensitive materials, such deformation may directly affect their dimensional accuracy and structural strength, which may lead to a decrease in the coating qualification rate or even cause processing failure.
[0006] To achieve the above objectives, the present invention adopts the following technical solution:
[0007] An adaptive temperature-controlled plasma spraying device includes a mounting frame and further includes: an adjustment mechanism located on the mounting frame, the adjustment mechanism including a six-axis robotic arm and two air supply pipes, one end of the six-axis robotic arm being fixedly connected to a connecting pipe, one end of the connecting pipe being provided with a plasma spray gun, a material supply pipe being provided on the outer wall of the connecting pipe, a dust collection hood being threadedly connected to the outer wall of the connecting pipe, a cooling component and a dust suction component being provided on the inner wall of the dust collection hood, one end of the two air supply pipes penetrating through the outer wall of the dust collection hood, a connecting cavity and several spray channels being opened inside the cooling component, one end of the air supply pipe communicating with the connecting cavity, the spray channels communicating with the connecting cavity, the spray channels extending to the bottom outer wall of the cooling component, and one end of the spray channels being provided with a nozzle; and a limiting mechanism located on one side of the mounting frame.
[0008] By adopting the above technical solution, the cooling intensity and spraying path can be dynamically adjusted to ensure that the temperature always meets the process requirements, improve the uniformity and bonding strength of the coating, and prevent the workpiece from deforming due to local high temperature. Specifically, after the device is started, the infrared thermal imaging sensor scans the surface temperature distribution of the workpiece in real time, generates temperature data and transmits it to the PID controller. The PID controller dynamically adjusts the airflow intensity of the nozzle (by controlling the air pressure or flow rate of the air supply pipe) according to the deviation between the preset temperature curve and the real-time data, so as to achieve precise control of the substrate surface temperature. The six-axis robotic arm carries the plasma spray gun and moves along the preset path. The plasma beam melts the spraying material and deposits it on the surface of the workpiece. The cooling component inputs inert gas or atomized coolant through the air supply pipe and sprays it out at high speed from the nozzle through the internal spray channel, forming a local air curtain in the spraying area, which quickly removes heat and prevents the substrate from overheating and deforming. The dust collection hood simultaneously adsorbs the splashed dust generated during the spraying process through the dust collection component, avoiding environmental pollution and affecting the coating quality. The cooling airflow and negative pressure dust collection work together to further reduce the risk of dust diffusion.
[0009] In a preferred embodiment, the bottom outer wall of the cooling assembly is provided with four temperature sensors that are equidistantly distributed, and the four temperature sensors are distributed alternately with a number of nozzles.
[0010] In this solution, the layout of four temperature sensors can cover the main working area directly below the cooling component, providing real-time feedback on the temperature distribution of the substrate surface, eliminating blind spots in single-point temperature measurement, improving the response speed and accuracy of PID control, and the phased distribution design allows the cooling airflow intensity of each nozzle to be dynamically adjusted according to the temperature of the corresponding area, avoiding local overcooling or overheating, and ensuring consistent coating quality.
[0011] In a preferred embodiment, the limiting mechanism includes a connecting frame, the top outer wall of the connecting frame is provided with a third electric slide rail, two moving blocks are slidably connected on the third electric slide rail, a motor is provided inside the moving blocks, a limiting post is provided on the top outer wall of the moving blocks, a threaded rod is provided inside the limiting post, one end of the threaded rod is fixedly connected to the output shaft of the motor, a clamping plate is threadedly connected to the outer wall of the threaded rod, and a pneumatic clamp is provided on one side outer wall of the clamping plate.
[0012] In this solution, the third electric slide rail drives the moving block to a preset position, aligning the limit post with the working boundary of the six-axis robotic arm. The motor adjusts the height of the clamping plate via a threaded rod to accommodate workpieces or fixtures of different sizes, reducing the need for operators to manually adjust the workpiece height. This reduces the degree of human intervention, minimizes operational errors, and improves overall production efficiency. When the pneumatic fixture is activated, it uses air pressure or vacuum to adsorb and fix the workpiece. When it is necessary to release the workpiece, the gas source is controlled to release gas, causing the pneumatic fixture to lose its clamping force, thereby releasing the workpiece.
[0013] As described above, the adaptive temperature-controlled plasma spraying device includes a mounting frame and further includes: an adjustment mechanism located on the mounting frame, comprising a six-axis robotic arm and two gas supply pipes. One end of the six-axis robotic arm is fixedly connected to a connecting pipe, and one end of the connecting pipe is equipped with a plasma spray gun. A material supply pipe is provided on the outer wall of the connecting pipe, and a dust collection hood is threadedly connected to the outer wall of the connecting pipe. The inner wall of the dust collection hood is equipped with a cooling component and a dust suction component. One end of each of the two gas supply pipes penetrates through the outer wall of the dust collection hood. The cooling component has a communicating cavity and several spray channels inside. One end of each gas supply pipe communicates with the communicating cavity, and the spray channels communicate with the communicating cavity. The spray channels extend to the bottom outer wall of the cooling component, and one end of each spray channel is equipped with a nozzle. A limiting mechanism is located on one side of the mounting frame. The adaptive temperature-controlled plasma spraying device provided by this utility model has the technical effect of dynamically adjusting the cooling intensity and spraying path to ensure that the temperature always meets the process requirements, thereby improving the coating uniformity and bonding strength. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the overall structure of the adaptive temperature control plasma spraying device proposed in this utility model.
[0015] Figure 2 This is a schematic diagram of the limiting mechanism of the adaptive temperature control plasma spraying device proposed in this utility model.
[0016] Figure 3 This is a schematic diagram of the dust collection component of the adaptive temperature control plasma spraying device proposed in this utility model.
[0017] Figure 4 This is a cross-sectional view of the adjustment mechanism of the adaptive temperature control plasma spraying device proposed in this utility model.
[0018] Figure 5 This is a schematic diagram of the cooling component structure of the adaptive temperature control plasma spraying device proposed in this utility model.
[0019] In the attached diagram: 1. Mounting bracket; 2. First electric slide rail; 3. Connecting plate; 4. Six-axis robotic arm; 5. Second electric slide rail; 6. Third electric slide rail; 7. Connecting pipe; 8. Material conveying pipe; 9. Air conveying pipe; 10. Air pump; 11. Dust collection hood; 12. Limiting post; 13. Threaded rod; 14. Clamping plate; 15. Pneumatic clamp; 16. Connecting frame; 17. Motor; 18. Cooling assembly; 19. Plasma spray gun; 20. Temperature sensor; 21. Nozzle; 22. Dust suction port; 23. Storage chamber; 24. Connecting chamber. Detailed Implementation
[0020] 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 marked in the accompanying drawings can be arranged and designed in various different configurations. 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 represents selected embodiments of this 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.
[0021] The adaptive temperature control plasma spraying device disclosed in this utility model is mainly used in traditional plasma spraying fixtures that usually lack dynamic temperature control functions. During the spraying process, the surface temperature of the substrate fluctuates significantly, which can easily lead to problems such as uneven coating thickness and insufficient adhesion. If the local temperature is too high during spraying, the workpiece is prone to thermal deformation. Especially for thin-walled parts or heat-sensitive materials, this deformation may directly affect its dimensional accuracy and structural strength, which may lead to a decrease in the coating qualification rate or even cause processing failure.
[0022] Reference Figure 1 , Figure 3 , Figure 4 and Figure 5An adaptive temperature-controlled plasma spraying device includes a mounting frame 1 and further includes: an adjustment mechanism located on the mounting frame 1, the adjustment mechanism including a six-axis robotic arm 4 and two air supply pipes 9, one end of the six-axis robotic arm 4 is fixedly connected to a connecting pipe 7, one end of the connecting pipe 7 is provided with a plasma spray gun 19, the outer wall of the connecting pipe 7 is provided with a material supply pipe 8, the outer wall of the connecting pipe 7 is connected to a dust collection hood 11 by threads, the inner wall of the dust collection hood 11 is provided with a cooling component 18 and a dust suction component, one end of the two air supply pipes 9 penetrates through the outer wall of the dust collection hood 11, the cooling component 18 has a connecting cavity 24 and several spray channels inside, one end of the air supply pipe 9 is connected to the connecting cavity 24, the spray channels are connected to the connecting cavity 24, the spray channels extend to the bottom outer wall of the cooling component 18, and one end of the spray channels is provided with a nozzle 21; and a limiting mechanism located on one side of the mounting frame 1.
[0023] The dust collection hood 11 and the cooling component 18 are both frustum-shaped mechanisms. The frustum shape allows the cooling gas, inert gas, or atomized liquid to form a laminar air curtain when sprayed from the nozzle 21, resulting in a larger coverage area and more uniform distribution. This avoids local overcooling or overheating. In addition, the conical opening design expands the dust collection range. Together with the dust collection component, it can more efficiently capture splashed molten particles and dust, reducing secondary pollution.
[0024] During use, the top outer wall of the mounting frame 1 is provided with a first electric slide rail 2, and the bottom outer wall of the six-axis robotic arm 4 is provided with a connecting plate 3. The connecting plate 3 is slidably connected to the first electric slide rail 2. The six-axis robotic arm 4 carries the plasma spray gun 19 and can realize multi-angle spraying in space. Furthermore, the six-axis robotic arm 4 can freely adjust the end posture within the stroke of the first electric slide rail 2 to adapt to the spraying requirements of complex curved workpieces.
[0025] The cooling assembly 18 has four temperature sensors 20 evenly distributed on its bottom outer wall, and these four temperature sensors 20 are interspersed with several nozzles 21. The temperature sensors 20 are fixed to the outer wall of the cooling assembly 18 by embedded mounting or flange, and their signal lines are led out through the internal channels of the cooling assembly 18 to avoid interference from high temperature, dust or cooling airflow, ensuring the reliability of data acquisition. The temperature sensors 20 are infrared thermal imaging sensors. The layout of the four temperature sensors 20 can cover the main working area directly below the cooling assembly 18, providing real-time feedback on the surface temperature distribution of the substrate, eliminating blind spots in single-point temperature measurement, and improving the response speed and accuracy of PID control. The interspersed design allows the cooling airflow intensity of each nozzle 21 to be dynamically adjusted according to the temperature of the corresponding area, avoiding local overcooling or overheating and ensuring consistent coating quality.
[0026] It should be noted that the gas supply pipe 9 is equipped with a regulating valve inside, and a PID controller is installed on one side of the outer wall of the mounting bracket 1. The PID controller is connected to the temperature sensor 20 and the regulating valve of the gas supply pipe 9, such as a pneumatic valve or an electric regulating valve, respectively, through signal lines (not shown) to achieve closed-loop control and adjust the airflow intensity of the gas supply pipe 9 according to the preset temperature curve. Although the attached figure does not directly show the physical location of the PID controller, as a core control unit, it must exist in the electrical control system of the device. The specific location can be flexibly adjusted according to the actual installation requirements, such as on one side of the mounting bracket 1 or in an external control box, without affecting its function.
[0027] In the specific implementation process, the dust collection component includes an air pump 10, which is fixedly installed on the outer wall of the dust collection hood 11. Several dust collection ports 22 are opened on the inner wall of the cooling component 18. The dust collection ports 22 are located between two adjacent spray channels. A storage chamber 23 is opened inside the dust collection hood 11. The position of the storage chamber 23 corresponds to the distribution position of the dust collection ports 22. The air inlet end of the air pump 10 is connected to the storage chamber 23.
[0028] In particular, the outlet of the vacuum pump 10 is fixedly connected to the collection system. Although the collection system, such as a dust collection box, filter device, or gas purification equipment, is not specifically shown in the drawings, it is a necessary extension of the dust collection component. It is usually connected to the outlet of the dust collection hood 11 through a pipe to receive and process the dust-laden airflow discharged by the vacuum pump 10. The reason why the collection system is not shown in the drawings is that the core innovation of this patent lies in the synergistic structural design of the cooling component 18 and the dust collection component, rather than the specific form of the collection system. Therefore, the drawings focus on the key components of the device, such as the dust collection hood 11, the cooling component 18, and the nozzle 21, to highlight the technical improvement. The suction port 22 and the spray channel are staggered, which not only avoids the cooling airflow from interfering with the dust collection effect, but also directly captures the dust suspended under the disturbance of the cooling airflow. When the vacuum pump 10 is running, a stable negative pressure is formed in the storage chamber 23, which accelerates the directional delivery of dust to the collection system. The dust is sucked away in time, avoiding the molten particles from re-adhering to the surface of the workpiece to form defects such as pits and pores, and improving the density of the coating.
[0029] Specifically, after the device is started, the infrared thermal imaging sensor scans the surface temperature distribution of the workpiece in real time, generates temperature data and transmits it to the PID controller. The PID controller dynamically adjusts the airflow intensity of the nozzle 21 according to the deviation between the preset temperature curve and the real-time data, and controls the air pressure or flow rate of the air supply pipe 9 to achieve precise control of the substrate surface temperature. The six-axis robotic arm 4 carries the plasma spray gun 19 and moves along the preset path. The plasma beam melts the spraying material and deposits it on the surface of the workpiece. The cooling component 18 inputs inert gas or atomized coolant through the air supply pipe 9 and sprays it out at high speed from the nozzle 21 through the internal spray channel, forming a local air curtain in the spraying area, quickly removing heat and preventing the substrate from overheating and deforming. The dust collection hood 11 simultaneously adsorbs the splashed dust generated during the spraying process through the dust collection component to avoid environmental pollution and affecting the coating quality. The cooling airflow and negative pressure dust collection work together to further reduce the risk of dust diffusion. The temperature sensor 20 provides real-time feedback data and dynamically adjusts the cooling intensity and spraying path to ensure that the temperature always meets the process requirements and improves the coating uniformity and bonding strength.
[0030] Reference Figure 1 and Figure 2 In a preferred embodiment, the limiting mechanism includes a connecting frame 16, a third electric slide rail 6 is provided on the top outer wall of the connecting frame 16, two moving blocks are slidably connected on the third electric slide rail 6, a motor 17 is provided inside the moving blocks, a limiting post 12 is provided on the top outer wall of the moving blocks, a threaded rod 13 is provided inside the limiting post 12, one end of the threaded rod 13 is fixedly connected to the output shaft of the motor 17, a clamping plate 14 is threadedly connected to the outer wall of the threaded rod 13, and a pneumatic clamp 15 is provided on one side outer wall of the clamping plate 14.
[0031] It should be noted that the pneumatic clamp 15 uses a contoured silicone pad in conjunction with vacuum adsorption to ensure that the curved surface fits the surface of the irregularly shaped workpiece.
[0032] Specifically, the third electric slide rail 6 drives the moving block to a preset position, aligning the limit post 12 with the working boundary of the six-axis robotic arm 4. The motor 17 adjusts the height of the clamping plate 14 via the threaded rod 13 to accommodate workpieces or fixtures of different sizes, reducing the need for operators to manually adjust the workpiece height. This reduces the degree of manual intervention, decreases operational errors, and improves overall production efficiency. When the pneumatic clamping fixture 15 is started, it uses air pressure or vacuum to adsorb and fix the workpiece. When it is necessary to release the workpiece, the gas source is controlled to release gas, causing the pneumatic clamping fixture 15 to lose its clamping force, thereby releasing the workpiece.
[0033] Reference Figure 1 and Figure 2In a preferred embodiment, two second electric slide rails 5 are fixedly installed on one outer wall of the mounting frame 1, and the two sides of the connecting frame 16 are slidably connected to the two second electric slide rails 5 respectively, so as to drive the connecting frame 16 of the limiting mechanism to move flexibly along the Y-axis direction, thereby realizing the dynamic adjustment of the relative position between the limiting mechanism and the six-axis robotic arm 4.
[0034] Working principle: After the device is started, the infrared thermal imaging sensor scans the surface temperature distribution of the workpiece in real time, generates temperature data and transmits it to the PID controller. The PID controller dynamically adjusts the airflow intensity of the nozzle 21 according to the deviation between the preset temperature curve and the real-time data, and controls the air pressure or flow rate of the air supply pipe 9 to achieve precise control of the substrate surface temperature. The six-axis robotic arm 4 carries the plasma spray gun 19 and moves along the preset path. The plasma beam melts the spraying material and deposits it on the surface of the workpiece. The cooling component 18 inputs inert gas or atomized coolant through the air supply pipe 9 and sprays it out at high speed from the nozzle 21 through the internal spray channel, forming a local air curtain in the spraying area, which quickly removes heat and prevents the substrate from overheating and deforming. The dust collection hood 11 simultaneously adsorbs the splashed dust generated during the spraying process through the dust collection component to avoid environmental pollution and affect the coating quality. The cooling airflow and negative pressure dust collection work together to further reduce the risk of dust diffusion. The temperature sensor 20 provides real-time feedback data and dynamically adjusts the cooling intensity and spraying path to ensure that the temperature always meets the process requirements and improves the coating uniformity and bonding strength.
[0035] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. The substitutions may be replacements of some structures, devices, or method steps, or they may be complete technical solutions. Equivalent substitutions or modifications made based on the technical solution and inventive concept of this utility model should all be covered within the protection scope of this utility model.
Claims
1. An adaptive temperature-controlled plasma spraying apparatus, comprising a mounting bracket (1), characterized in that, Also includes: Adjustment mechanism: Located on the mounting frame (1), the adjustment mechanism includes a six-axis robotic arm (4) and two air supply pipes (9). One end of the six-axis robotic arm (4) is fixedly connected to a connecting pipe (7). One end of the connecting pipe (7) is provided with a plasma spray gun (19). The outer wall of the connecting pipe (7) is provided with a material supply pipe (8). The outer wall of the connecting pipe (7) is connected to a dust collection hood (11) by a thread. The inner wall of the dust collection hood (11) is provided with a cooling component (18) and a dust suction component. One end of the two air supply pipes (9) passes through the outer wall of the dust collection hood (11). The interior of the cooling component (18) is provided with a connecting cavity (24) and several spray channels. One end of the air supply pipe (9) is connected to the connecting cavity (24). The spray channels are connected to the connecting cavity (24). The spray channels extend to the bottom outer wall of the cooling component (18), and one end of the spray channels is provided with a nozzle (21). Limiting mechanism: located on one side of the mounting bracket (1).
2. The adaptive temperature-controlled plasma spraying apparatus according to claim 1, characterized in that, Both the dust collection hood (11) and the cooling assembly (18) are frustum-shaped mechanisms.
3. The adaptive temperature-controlled plasma spraying apparatus according to claim 2, characterized in that, The top outer wall of the mounting bracket (1) is provided with a first electric slide rail (2), and the bottom outer wall of the six-axis robotic arm (4) is provided with a connecting plate (3), which is slidably connected to the first electric slide rail (2).
4. The adaptive temperature-controlled plasma spraying apparatus according to claim 1, characterized in that, The bottom outer wall of the cooling assembly (18) is provided with four temperature sensors (20) distributed at equal intervals, and the four temperature sensors (20) are distributed alternately with a number of nozzles (21).
5. The adaptive temperature-controlled plasma spraying apparatus according to claim 4, characterized in that, The dust collection assembly includes an air pump (10), which is fixedly installed on the outer wall of the dust collection hood (11). The inner wall of the cooling assembly (18) is provided with a plurality of dust suction ports (22), which are located between two adjacent spray channels. The dust collection hood (11) is provided with a storage cavity (23), the position of which corresponds to the distribution position of the dust suction ports (22). The air inlet of the air pump (10) is connected to the storage cavity (23).
6. The adaptive temperature-controlled plasma spraying apparatus according to claim 1, characterized in that, The limiting mechanism includes a connecting frame (16), the top outer wall of the connecting frame (16) is provided with a third electric slide rail (6), two moving blocks are slidably connected on the third electric slide rail (6), a motor (17) is provided inside the moving block, a limiting post (12) is provided on the top outer wall of the moving block, a threaded rod (13) is provided inside the limiting post (12), one end of the threaded rod (13) is fixedly connected to the output shaft of the motor (17), a clamping plate (14) is connected to the outer wall of the threaded rod (13) by threads, and a pneumatic clamp (15) is provided on one side outer wall of the clamping plate (14).
7. The adaptive temperature-controlled plasma spraying apparatus according to claim 6, characterized in that, Two second electric slide rails (5) are fixedly installed on one outer wall of the mounting bracket (1), and the two sides of the connecting bracket (16) are slidably connected to the two second electric slide rails (5).