Paint distributor and valve arrangement

Abstract

Paint distributor comprising a body with a fluid channel running through it, a first valve with a valve tip positioned near the fluid channel, a second valve with a valve tip positioned near the fluid channel, and a third valve with a valve tip positioned near the fluid channel. The distributor also includes a paint supply channel running through the body and connected to the first valve, a paint return channel running through the body and connected to the first valve, a paint supply channel running through the body and connected to the second valve, a paint return channel running through the body and connected to the second valve, a paint supply channel running through the body and connected to the third valve, and a paint return channel running through the body and connected to the third valve.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 63 / 583,100, filed September 15, 2023, entitled "Color Manifold and Valve Assembly," which is expressly incorporated herein by reference in its entirety. STATE OF THE ARTTechnical field

[0002] This disclosure relates generally to a fluid manifold, and more particularly to a paint manifold for a robotic paint delivery system comprising three valves positioned in a common plane and each having a valve tip positioned near a central paint channel. Discussion of related technology

[0003] Robots are known to perform a variety of tasks, including painting an object, such as a vehicle body. A typical robotic paint station for painting, for example, the exterior surfaces of vehicle bodies in both continuous-feed and stop-stop systems includes a paint booth, a plurality of painting robots, and opening / closing robots arranged around its perimeter. These robots can be mounted on the floor, a wall, a ceiling, or on side rails. The painting robots are equipped with either spray guns or rotary applicators to direct atomized paint onto the vehicle body.

[0004] A typical paint delivery system for a painting robot includes a paint manifold with a series of valves controlled to selectively deliver paints of different colors to a fluid manifold, which measures and controls the paint flow to the paint applicator. Automotive paint is expensive, and therefore efforts are made to limit paint waste. One way to do this is to reduce the amount of paint left in the manifolds at the end of a painting job. This paint is usually diverted to a paint drain to clean the manifolds for the next painting job. The distance the paint must travel through hoses and passageways in these manifolds varies depending on the design. One way to reduce the amount of paint left in the manifolds at the end of a painting job is to reduce the distance the paint must travel from the paint source to the applicator. SUMMARY OF THE INVENTION

[0005] The following discussion discloses and describes a paint manifold comprising a body having a fluid passage therethrough, a first valve extending into the body and having a valve tip positioned proximate the fluid passage, a second valve extending into the body and having a valve tip positioned proximate the fluid passage, and a third valve extending into the body and having a valve tip positioned proximate the fluid passage. Each valve includes a valve stem seal with sealing surfaces that seal against the body and a valve seat with a hemispherical surface.The manifold also includes a fluid supply channel passing through the body and connected to the first valve, a fluid return channel passing through the body and connected to the first valve, a fluid supply channel passing through the body and connected to the second valve, a fluid return channel passing through the body and connected to the second valve, a fluid supply channel passing through the body and connected to the third valve, and a fluid return channel passing through the body and connected to the third valve.

[0006] Further features of the present disclosure will become apparent from the following description and the appended claims taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an isometric view of a painting robot; Fig. 2 is a schematic diagram of a paint supply system comprising a paint distributor and a paint canister, which is connected to the Fig. 1 can be used; Fig. 3 is a schematic diagram of another paint supply system comprising a paint distributor and a pump distributor, which is compatible with the Fig. 1 can be used; Fig. 4 is an isometric front view of a paint distributor used as the paint distributor in the Fig. 2 and Fig. 3 can be used with the paint supply systems shown; Fig. 5 is an isometric rear view of the Fig. 4 shown paint distributor; Fig. 6 is a front view of the Fig. 4 shown paint distributor; Fig. 7 is a rear view of the Fig. 4 shown paint distributor; Fig. 8 is a side view of the Fig. 4 shown paint distributor; Fig. 9 is a plan view of the Fig. 4 shown paint distributor; Fig. 10 is a rear view of the Fig. 4 with a transparent block to show the fluid channels therein; Fig. 11 is an isometric view of the paint manifold showing bushings for valves positioned therein; and Fig. Figure 12 is a cutaway front view of the paint manifold showing a cross-sectional view of one of the valves positioned therein. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0007] The following discussion of embodiments of the disclosure pertaining to a paint dispenser for a robotic paint delivery system including three valves positioned in a common plane and each having a valve tip positioned near a central fluid channel is exemplary in nature and is not intended to limit the invention or its applications or uses in any way. For example, although the discussion herein specifically relates to a paint delivery system for a painting robot painting a vehicle part, the paint delivery system may also be used to dispense other coatings or fluids through other devices for other applications.

[0008] Fig. 1 is an isometric view of a painting robot 10 mounted on a stationary base 12, wherein the robot 10 is intended to represent any painting robot suitable for the purposes discussed herein. A turret or robot base 14 is rotatably mounted to the base 12. An inner arm 18 is rotatably connected to the base 14 by a joint 20, an outer arm 22 is rotatably connected to the inner arm 18 by a joint 24, and a wrist member 26 is rotatably connected to the outer arm 22 by a joint 28. An applicator 30 is fixedly attached to the wrist member 26 at an angle optimized for a painting application, and a paint spray 32 is shown being dispensed from the applicator 30.

[0009] Fig. 2 is a schematic block diagram of a paint supply system 40 used with the Fig. 1. It should be noted that while the discussion herein specifically relates to a painting robot painting, for example, a vehicle body, the paint delivery system 40 may also be used to dispense other coatings or liquids through other devices for other applications. The system 40 includes an applicator 42, such as a rotary atomizer, having a trigger valve 44 connected to a paint dispensing line 46. The various valves and manifolds in the system 40 may be mounted on the outer arm 22, and the applicator 42 would be part of an end effector on the robot 10. The system 40 also includes a paint manifold 50 having a plurality of paint valves 52 that are selectively opened to receive paint from a plurality of paint sources 54 and to provide the paint to an isolation line 58.The paint manifold 50 also includes a solvent valve 60 that is selectively opened to provide solvent from a solvent source 62 onto the isolation line 58. The paint manifold 50 also includes a blow-off valve 64 for venting solvent and air from the system 40 to a blow-off outlet 66. The paint manifold 50 further includes a vacuum valve 68 connected to a vacuum source to exhaust air from the channels in the system 40 before they are filled with paint.

[0010] The system 40 further includes a canister manifold 70 to which a paint canister 72 is attached, the canister 72 including a chamber 74. The canister 72 also includes a piston 76 defining a paint volume 78 within the intermediate chamber 74, which contains a predetermined amount of paint when the canister 72 is filled with paint, where the piston 76 may be pneumatically driven, fluid-driven, etc. A paint feed line 80 allows the volume 78 to be filled with paint from the isolation line 58 through a paint feed valve 82, and a paint discharge line 84 allows paint to be discharged from the paint volume 78 through a paint discharge valve 86 into the paint discharge line 46 by moving the piston 76. A pair of valves 88 and 90 in the manifold 70 allow the various lines in the manifold 70 to be solvent-cleaned and dried in a manner well understood by those skilled in the art.

[0011] The system 40 also includes a cleaning manifold 92 with valves 94, 96, and 98 connected to valves 88 and 90 in the manifold 70 by an insulating line 100. A solvent source 102 supplies solvent to the manifold 92 through valve 98. An air source 104 supplies drying air to the manifold 92 through valve 94. During the painting process, the paint canister 72 and the applicator 44 are under high voltage, and the paint manifold 50 and the manifold 92 are grounded by a liquid supply. Therefore, the canister 72 must be electrically isolated from the paint manifold 50 and the cleaning manifold 92 to prevent ground faults. The insulating lines 58 and 100 are therefore empty and clean during the painting process to provide electrical isolation.

[0012] Fig. Figure 3 is a schematic diagram of another paint delivery system 110 that may be used with the painting robot 10. The system 110 includes a solvent / air manifold 112, a paint manifold 114, and a pump manifold 116, all connected to a common fluid line 120. The pump manifold 116 supplies an applicator 118, representing, for example, applicator 30, on line 180 with paint to be dispensed onto the part. The solvent / air manifold 112 receives a cleaning solvent from a solvent source 124 and air from an air source 126. The solvent is provided through a flow regulator 132 to a solvent valve 130 and then to a control valve 134. A solvent valve 140 allows the solvent to bypass the flow regulator 132 and the control valve 134.Air is provided to an air valve 142, and solvent and / or air are / is provided to a solvent supply valve 144. The paint manifold 114 includes three paint valves 146 that selectively allow paint to be provided on the line 120, and may be the paint manifold discussed in detail below. It should be noted that other embodiments of the system 110 may support multiple paint manifolds to provide more paint colors from more sources.

[0013] The pump manifold 116 includes a pressure regulator 150 that regulates the fluid flow on line 120, an inlet sensor 152 that measures the fluid pressure on line 120 at the inlet of the pump manifold 116, and an outlet sensor 154 that measures the fluid pressure on line 120 at the outlet of the pump manifold 116. The pump manifold 116 also includes a pump 156 that pumps the fluids through the system 110. A blow-off valve 158 on an inlet side of the pump 156 allows solvent or air to be discharged from the system 110, and a blow-off valve 160 on an outlet side of the pump 156 allows solvent or air to be discharged from the system 110. A flush valve 162 allows the pump manifold 116 to be flushed with solvent on line 164. The applicator 118 receives paint from the pump manifold 116 on line 180 and dispenses it through a paint inlet valve 170 and a release valve 172.Air and solvent are provided from valve 144 on line 182 to applicator cleaning valves 174, 176 and 178.

[0014] As will be well understood by one skilled in the art, the various valves, pumps, flow controllers, and other devices in system 110 are appropriately controlled to dispense paint from one of the paint sources through one of the paint valves 146, through the pump manifold 116 on line 120, through line 180, and through valves 170 and 172 to be dispensed by the applicator 118.

[0015] Fig. 4 is an isometric front view, Fig. 5 is an isometric rear view, Fig. 6 is a front view, Fig. 7 is a rear view, Fig. 8 is a side view and Fig. 9 is a plan view of a paint distributor 200 which is part of the paint distributor 50 in the Fig. 2 shown paint supply system 40 and the paint distributor 114 in the Fig. 3. The paint manifold 200 includes a specially shaped block 202, made of, for example, acetal copolymer, which may have various appearances and features, as shown. It should be noted that the block shape of the manifold 200 is merely a non-limiting example, as other shapes, such as semi-circular, may be used. The block 202 includes a front side 204, a back side 206, a left side 208, a right side 210, and a top side 212. In one non-limiting embodiment, the block 202 has a depth of 18 to 58 mm between the front side 204 and the back side 206. The front side 204 includes recesses 220 and 222 that are open to the top side 212 and include a mating step 224 and 226, respectively. The top surface 212 includes a recess 232 and the block 202 includes a V-cut feature 234 at the bottom of the block 202.A central channel 236 extends through the block 202 from the front side 204 to the back side 206, and a pair of alignment bosses 244 and 246 extend from the back side 206 of the block 202.

[0016] Fig. 10 is a front view of the paint manifold 200, with the block 202 shown in phantom to show the fluid channels therein. The paint manifold 200 includes a valve 260 extending through the recess 232 in the top 212 into the block 202, a valve 262 extending through the left side 208 into the block 202, and a valve 264 extending through the right side 210 into the block 202. Ends of the valves 260, 262, and 264 are positioned near the central channel 236, and the valves 260, 262, and 264 are positioned on the same plane. The orientation angle of the valves 260, 262 and 264 relative to each other may be any angle suitable for the purposes discussed herein, for example in a range of 85° to 125°.Valve 260 includes an air fitting 270 connected to an end of valve 260 opposite central channel 236, valve 262 includes an air fitting 272 connected to an end of valve 262 opposite central channel 236, and valve 264 includes an air fitting 274 connected to an end of valve 264 opposite central channel 236. The design of valves 260, 262, and 264 minimizes the distance paint travels through central channel 236 when the respective valve 260-264 is open, reducing paint waste.

[0017] Fig. 11 is an isometric view of block 202 without valves 260, 262, and 264. Block 202 includes a valve bushing 266 having a configuration and features for receiving valve 260 such that block 202 functions as a valve housing for valve 260. Similarly, block 202 includes a valve bushing 268 having a configuration and features for receiving valve 262 such that block 202 functions as a valve housing for valve 262. Likewise, block 202 includes a valve bushing 276 having a configuration and features for receiving valve 264 such that block 202 functions as a valve housing for valve 264.

[0018] Each valve 260, 262, and 264 allows paint to flow from a different paint source to the central channel 236. A supply channel 280 is connected to the valve 260 and a supply port socket 316 in the block 202 through the top 212, and a return channel 284 is connected to the valve 260 and a return port socket 298 in the block 202 through the top 212, with a paint fitting 320 inserted into the socket 316 and a paint fitting 302 inserted into the socket 298. When the valve 260 is closed, paint can circulate from a paint source through the supply channel 280, through a chamber in the valve 260, through the return channel 284, and back to the paint source. When the valve 260 is open, paint is directed from the supply channel 280 to the central channel 236.

[0019] Likewise, a supply channel 292 is connected to the valve 262 and a supply port socket 294 in the block 202 through the top 212, and a return channel 296 is connected to the valve 262 and a return port socket 286 in the block 202 through the top 212, with a paint fitting 300 inserted into the socket 294 and a paint fitting 290 inserted into the socket 286. When the valve 262 is closed, paint can circulate from a paint source through the supply channel 292, through a chamber in the valve 262, through the return channel 296, and back to the paint source. When the valve 262 is open, paint is directed from the supply channel 292 to the central channel 236.

[0020] Likewise, a supply channel 310 is connected to the valve 264 and a supply port socket 312 in the block 202 through the top 212, and a return channel 314 is connected to the valve 264 and a return port socket 282 in the block 202 through the top 212, with a paint fitting 318 inserted into the socket 312 and a paint fitting 288 inserted into the socket 282. When the valve 264 is closed, paint can circulate from a paint source through the supply channel 310, through a chamber in the valve 264, through the return channel 314, and back to the paint source. When the valve 264 is open, paint is directed from the supply channel 310 to the central channel 236.It should be noted that the arrangement of bushings 282, 312 and 316 requires a boss 328 and that the arrangement of bushings 286, 294 and 298 requires a boss 338 to allow multiple manifolds to be stacked back to back, since the recesses 220 and 222 serve as a mating cutout for the bosses of adjacent manifolds.

[0021] A leakage channel 322 provides a visual indication of seals on the fluid side of valve 260, a leakage channel 324 provides a visual indication of seals on the fluid side of valve 262, and a leakage channel 326 provides a visual indication of seals on the fluid side of valve 264.

[0022] Fig.12 is a cutaway front view of the paint manifold 200 showing a cross-sectional view of the valve 260 positioned within the sleeve 266, assuming that the valves 262 and 264 are similar to the valve 260. The valve 260 includes an air side 330 having an air chamber 332 that receives control air, and a liquid side 334 having a paint chamber 336 that receives the paint from the supply channel 280. The valve 260 further includes a valve stem 340 extending the length of the valve 260 and connected to a valve tip 374 that seats within a valve seat 372 having a hemispherical surface. A control channel 342 extends through the valve stem 340 to provide control air to the air chamber 332. A valve cap 350 is provided over the valve stem 340 and a valve spring 354 is provided between the valve cap 350 and the valve stem 340.A piston seal 360 and a control-side seal 362 seal the air chamber 332, and fluid-side stem seals 370 seal the paint chamber 336. A seal retainer 368 holds the control-side seal 362 in place, preventing control air from entering the paint chamber 336. A leak channel 366 is in fluid communication with the leak channel 322.

[0023] When control air is supplied to the control channel 342, the air chamber 332 is pressurized, causing the valve stem 340 to move upward against the bias of the spring 354 and disengage the valve tip 374 from the valve seat 372, allowing paint to be dispensed from the paint chamber 336 into the central channel 236. When the control air is removed, the spring 354 pushes the valve stem 340 downward, causing the valve tip 374 to re-seat in the valve seat 372 and closing the valve 260.

[0024] In conventional valve designs, fluid-side stem seals seal the valve stem at the seal inner diameter and the valve body at the seal outer diameter. However, in the manifold 200, the fluid-side stem seals 370 seal directly on the block 202 at the outer diameter of the seals 370. Because the block 202 acts as the valve body for the valves 260, 262, and 264, the paint manifold 200 has a more compact design and reduces costs by eliminating the external O-ring seals required in the conventional valve design. Furthermore, eliminating the valve body allows the supply channels 280, 292, and 310 and the return channels 284, 296, and 314 to be angled relative to the respective valves 260, 262, and 264, which also contributes to the compact design of the paint manifold 200.The seal retainer 368 provides a retention means for the control-side seal 362 and allows the use of a conventional dynamic seal. The seal retainer 368 also includes features that form a seal with the block 202 without the need for an elastomeric seal. The valve seat 372 minimizes the size of the seat 372 around the valve tip 374 to allow for closer spacing between the valves 260, 262, and 264, which is achieved by moving the retention means of the seat 372 away from the valve tip 374. This closer spacing is made possible by the hemispherical outer shape of the seat 372. In another embodiment providing such closer spacing, the seat 372 includes a generally conical outer shape.In yet another embodiment enabling such closer spacing, a one-piece construction may be provided in which the seats 372 for the valves 260, 262, and 264 are combined into a single component. The design of the valve stem 340 allows the air fitting 270 to be directly connected to the stem 340.

[0025] The foregoing discussion discloses and describes only exemplary embodiments of the present disclosure. One skilled in the art will readily appreciate, from this discussion and the accompanying drawings and claims, that various changes, modifications, and variations may be made therein without departing from the spirit and scope of the disclosure as defined by the following claims.

Claims

[1] Liquid distributor, comprising: a body comprising a fluid channel passing therethrough; a first valve extending into the body and having a valve tip positioned proximate the fluid channel; a second valve extending into the body and having a valve tip positioned near the fluid channel; and a third valve extending into the body and having a valve tip positioned proximate the fluid passage, each valve including a valve stem seal having sealing surfaces that seal against the body. [2] The manifold of claim 1, wherein the body is a block including a front, a back, a left side, a right side, and a top, the fluid passage passing through the block between the front and back. [3] The manifold of claim 2, wherein the first valve extends through the top into the block, the second valve extends through the right side into the block, and the third valve extends through the left side into the block. [4] A distributor according to claim 2, wherein the block has a thickness in the range of 18 to 58 mm between the front and the back. [5] A manifold according to claim 1, wherein the first, second and third valves each have a length along a common plane. [6] A manifold according to claim 5, wherein the first, second and third valves are oriented relative to each other at an angle between 85° and 125°. [7] The distributor of claim 1, further comprising a first fluid supply channel extending through the body and connected to the first valve, a first fluid return channel extending through the body and connected to the first valve, a second fluid supply channel extending through the body and connected to the second valve, a second fluid return channel extending through the body and connected to the second valve, a third fluid supply channel extending through the body and connected to the third valve, and a third fluid return channel extending through the body and connected to the third valve. [8] A distributor according to claim 1, wherein each valve comprises an air chamber and a liquid chamber, and wherein the air chamber is pressurized with air to actuate the valve. [9] A manifold according to claim 8, wherein each valve comprises a control-side seal sealing a control air chamber and a seal retainer retaining the control-side seal to prevent air from entering the liquid chamber. [10] A manifold according to claim 1, wherein each valve comprises a valve seat having a hemispherical surface. [11] A manifold according to claim 1, wherein each valve comprises a leakage channel in fluid communication with a leakage fluid channel extending through the body. [12] A distributor according to claim 1, wherein the distributor is part of a paint delivery system and the liquid is paint. [13] Distributor according to claim 12, wherein the paint supply system is part of a painting robot. [14] Paint distributor forming part of a paint supply system on a painting robot, the distributor comprising: a body comprising a front, a back, a left side, a right side and a top and a fluid channel extending through the body between the front and back; a first valve extending into the body and having a valve tip positioned proximate the fluid channel, the first valve extending through the top into the body; a second valve extending into the body and having a valve tip positioned near the fluid channel, the second valve extending through the right side into the body; and a third valve extending into the body and having a valve tip positioned proximate the fluid passage, the third valve extending through the left side into the body, and the first, second, and third valves each having a length along a common plane, and each valve including a valve stem seal having sealing surfaces sealing against the body and a valve seat having a hemispherical surface. [15] A distributor according to claim 14, wherein the body has a thickness in the range of 18 to 58 mm between the front and the back. [16] A manifold according to claim 14, wherein the first, second and third valves are oriented relative to each other at an angle between 85° and 125°. [17] The distributor of claim 14, further comprising a first fluid supply channel extending through the body and connected to the first valve, a first fluid return channel extending through the body and connected to the first valve, a second fluid supply channel extending through the body and connected to the second valve, a second fluid return channel extending through the body and connected to the second valve, a third fluid supply channel extending through the body and connected to the third valve, and a third fluid return channel extending through the body and connected to the third valve. [18] Paint distributor, comprising: a body comprising a fluid channel passing therethrough; a first valve extending into the body and having a valve tip positioned proximate the fluid channel; a second valve extending into the body and having a valve tip positioned near the fluid channel; a third valve extending into the body and having a valve tip positioned proximate the fluid passage, each valve comprising a valve stem seal having sealing surfaces sealing against the body and a valve seat having a hemispherical surface; a first fluid supply channel extending through the body and connected to the first valve; a first fluid return channel extending through the body and connected to the first valve; a second fluid supply channel extending through the body and connected to the second valve; a second fluid return channel extending through the body and connected to the second valve; a third fluid supply channel extending through the body and connected to the third valve; and a third fluid return channel passing through the body and connected to the third valve. [19] The manifold of claim 18, wherein the body is a block including a front, a back, a left side, a right side, and a top, the fluid passage extending through the block between the front and back, and the first valve extending through the top into the block, the second valve extending through the right side into the block, and the third valve extending through the left side into the block. [20] A manifold according to claim 18, wherein each valve comprises a leakage channel in fluid communication with a leakage channel extending through the body.

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