TEST DEVICE AND TEST PROCEDURES FOR ACOUSTIC FUNCTIONAL TESTING OF AN APPLICATION DEVICE

Description

[0001] The invention relates to a test device and a test method for the acoustic functional testing of an application device (e.g. rotary atomizer) that is used in a coating system (e.g. paint shop) for coating components (e.g. motor vehicle body components).

[0002] From DE 10 2015 006 161 A1, such a test device and a corresponding test method are known, which enable an acoustic functional test of a rotary atomizer. For this purpose, the rotary atomizer to be tested is inserted by the associated painting robot into a test container, which also serves as a cleaning device for cleaning the rotary atomizer. After the rotary atomizer has been inserted into the test container, it is then operated according to a test program, whereby microphones measure and evaluate the sound emissions of the rotary atomizer in order to carry out the functional test. Thus, faulty operating conditions of the rotary atomizer typically lead to a corresponding change in the sound emissions, which enables fault detection.

[0003] A disadvantage here is that the test container also serves to clean the rotary atomizer. Therefore, it is usually not possible to perform the functional test while the rotary atomizer is being cleaned. Furthermore, a relatively complex test container is required, since it also serves to clean the rotary atomizer.

[0004] For the technical background of the invention, reference should also be made to DE 10 2015 006 161 A1, DE 10 2012 006 567 A1, DE 196 19 000 A1, EP 0 849 592 A2, WO 2018 / 057087 A2, US 2016 / 151654 A1 and DE 197 25 048 A1.

[0005] The invention is therefore based on the objective of creating a correspondingly improved test device and a corresponding test method for the acoustic functional testing of an application device (e.g. rotary atomizer).

[0006] This problem is solved by a test device according to the invention or a corresponding test method according to the independent claims.

[0007] The test device according to the invention initially comprises, in accordance with the prior art described above, a test container which serves to hold the application device under test during an acoustic functional test. For this purpose, the application device under test is inserted into the test container in order to then perform the acoustic functional test.

[0008] The test device according to the invention is now distinguished from the prior art described at the outset in that the test container is movably arranged in the coating system, whereas the cleaning device serving as the test container is fixedly arranged in the coating system in the prior art described at the outset.

[0009] It should be noted that the test device according to the invention and the corresponding test method are suitable for the acoustic functional testing of various types of application devices. The invention is therefore not limited to the acoustic functional testing of rotary atomizers, as are known from the prior art. Rather, the invention is also suitable for the acoustic functional testing of other types of application devices, such as air atomizers, air-mixing devices, airless devices, or so-called pressure heads, which apply the coating material essentially without overspray.

[0010] In a preferred embodiment of the invention, the test device is integrated into a coating system (e.g., a paint shop) used for coating components (e.g., automotive body parts) with a coating agent, the coating agent being applied in a coating booth. To perform an acoustic functional test, the test container is moved into the coating booth. This offers the advantage that the acoustic functional test can be carried out on-site, meaning the application equipment under test does not need to be removed from the coating booth. During normal coating operation, however, the test container is moved out of the coating booth to avoid disrupting the process.

[0011] In a preferred embodiment of the invention, the test container is arranged on a transport sled that can be moved through the coating system, for example, along a coating line or a coating booth. Such transport sleds are known in the prior art and are also referred to as "skids." The test container can be attached to the transport sled so that it moves with the sled. For an acoustic functional test, the transport sled with the test container on it is moved into the coating booth, whereupon the functional test can be carried out inside the coating booth. Subsequently, the transport sled with the test container on it is moved out of the coating booth again so as not to disrupt normal coating operations.

[0012] The test container can be attached to the transport carriage by means of a lifting device. This lifting device allows the test container to be lifted from the transport carriage so that it can be positioned at an optimal height for an acoustic functional test.

[0013] Within the scope of the invention, it is also possible for several test containers to be attached to the transport carriage. For example, the test containers can be arranged one behind the other in the conveying direction or side by side with respect to the conveying direction.

[0014] The various test containers can be adapted to different types of application devices. For example, one test container might be designed for a rotary atomizer, while another is adapted for an air atomizer. The different test containers can therefore vary, for example, in size, the size of the inlet opening, and / or the shape of the inlet opening.

[0015] As briefly mentioned above, the test container has an insertion opening to allow the application device under test (e.g., rotary atomizer) to be inserted into the test container. Preferably, this insertion opening is located on the top of the test container, so that the application device under test is inserted vertically into the test container from above.

[0016] Furthermore, it should be noted that the test container has a seal to close the insertion opening when the application device is inserted into the test container. For an application device with a round cross-section, the insertion opening is preferably also round, so that an annular gap forms between the outer contour of the application device and the circumferential edge of the insertion opening, which can be sealed by the seal during the functional test.

[0017] The seal therefore has a ring-shaped circumferential sealing lip at the outer edge of the insertion opening, whereby the sealing lip rests in a sealing position against the application device when the application device is inserted into the test container.

[0018] Furthermore, the test container can have at least one movable opening flap that is movable between a closed and an open position. For example, two sliding opening flaps that move in opposite directions can be provided.

[0019] Furthermore, the test container can have a ventilation base which preferably runs transversely to the insertion direction and is permeable to air, such ventilation bases being known in the prior art.

[0020] Preferably, the underside of the test container has a drain opening to allow coating residue, cleaning agent residue, and / or compressed air to escape. This is particularly useful if the rotary atomizer under test emits steering air during the acoustic functional test, which must then escape from the test container.

[0021] In the preferred embodiment of the invention, the test container has a sound-absorbing soundproof lining on its inner side, which is intended to prevent sound reflections from the inner wall of the test container, since such sound reflections would interfere with the acoustic functional test. It is advantageous if the soundproof lining is replaceable so that it can be replaced if it becomes contaminated.

[0022] To perform the actual acoustic functional test, the test container has at least one sound sensor to detect sound emissions from the application device under test within the test container. The sound sensors can be, for example, microphones arranged inside the test container, preferably directed towards the interior of the test container.

[0023] It should be noted that several acoustic sensors are preferably arranged around the circumference of the test container. Furthermore, several acoustic sensors are preferably arranged one above the other in multiple levels within the test container. This offers the advantage that the acoustic emissions of the application device under test can also be evaluated in a direction-dependent manner.

[0024] Furthermore, the test container can include a reference sensor to detect ambient noise and subtract it from the sound emissions measured by the actual sound sensor. The reference sensor preferably has a primary measuring direction that points outwards through the inlet opening of the test container to specifically detect ambient noise.

[0025] It should be mentioned that the reference sensor is preferably located below the ventilation floor.

[0026] Furthermore, it should be mentioned that several reference sensors are preferably arranged in the test container, which are preferably oriented differently, which advantageously enables optimal suppression of ambient noise during the evaluation of the sound emissions.

[0027] Furthermore, the device according to the invention preferably also includes an evaluation unit that is connected to the sound sensor and preferably also to the reference sensor, and which performs the functional test by evaluating the sound emissions of the application device. However, the evaluation unit for evaluating the sound emissions is not necessarily part of the test device according to the invention. Rather, within the scope of the invention, it is also possible that the sound sensor and, if applicable, the reference sensor are connected to a separate external evaluation unit that is not part of the test device according to the invention.

[0028] Furthermore, it should be mentioned that the invention also claims protection for a transport sled (skid) known per se in the test device according to the invention, wherein the transport sled is characterized in that a test container for an acoustic functional test is arranged on the transport sled, as already described above.

[0029] Furthermore, the invention also includes the novel use of such a transport sled (skid) for the movable positioning of a test container for acoustic functional testing.

[0030] Furthermore, the invention also claims protection for a complete coating system with such a testing device or such a transport carriage.

[0031] Finally, the invention also claims protection for a corresponding testing method, wherein the individual process steps of the testing method according to the invention already result from the preceding description of the testing device according to the invention and therefore do not need to be described separately.

[0032] Other advantageous embodiments of the invention are characterized in the dependent claims or are explained in more detail below together with the description of the preferred embodiments of the invention with reference to the figures. The figures show: Figure 1 is a schematic representation of a transport sled (skid) with a test container mounted on it for an acoustic functional test; Figure 2 is a top view of the test container according to Figure 1Figure 3 a sectional view through the test container, Figure 4 a schematic representation of a transport sled (skid) with four different test containers mounted on it, Figure 5A a schematic representation of a painting system according to the invention during painting operation, wherein the transport sled with the test containers is located outside the painting booth, Figure 5B the painting system according to Figure 5A during the acoustic functional test, in which the transport carriage with the test containers is located inside the paint booth, as well as Figure 6 a flowchart to illustrate the test method according to the invention.

[0033] Figure 1 Figure 1 shows a schematic representation of a test container 1, which serves for the acoustic functional testing of a rotary atomizer 2, as shown in Figure 2. Figure 3As shown, the rotary atomizer 2 is inserted into the test container 1 through an insertion opening 4 by a painting robot 3, which is only shown schematically and in outline here, as is already known from the prior art cited at the beginning.

[0034] For this purpose, opening flaps 5, 6 are pushed outwards to release the insertion opening 4 of the test container 1 so that the rotary atomizer 2 can be inserted into the insertion opening 4.

[0035] During the actual functional test, a circumferential sealing lip 7 on the circumferential edge of the insertion opening 4 seals the annular gap between the outer contour of the rotary atomizer 2 and the circumferential edge of the insertion opening 4.

[0036] Firstly, this seal is advantageous to prevent ambient noise from entering the test container 1, as this ambient noise could interfere with the acoustic functional test of the rotary atomizer 2.

[0037] On the other hand, the sealing provided by the sealing lip 7 is also useful because during the acoustic functional test media (e.g. detergent, paint) can be released by the rotary atomizer 2 which should not escape to the outside.

[0038] To carry out the acoustic functional test, several sound sensors 8-11 are arranged in the test container 1, which are directed inwards towards the rotary atomizer 2 with their main measuring direction.

[0039] Furthermore, two reference sensors 13, 14 are arranged in the test container 1 below a ventilation base 12. Their main measuring direction is directed towards the inlet opening 4, and their purpose is to measure ambient noise so that this noise can then be subtracted from the sound emissions measured by the sound sensors 8-11. The ambient noise is preferably measured before the rotary atomizer 2 is inserted into the test container 1, as the inlet opening 4 is then still unobstructed.

[0040] Furthermore, it should be mentioned that the test vessel 1 has an internal sound-absorbing soundproof lining 15, which prevents the sound emissions of the rotary atomizer 2 from being reflected off the inner wall of the test vessel 1, as such sound reflections would impede the evaluation. It should also be noted that the soundproof lining 15 is replaceable, which is useful, for example, if the soundproof lining becomes contaminated.

[0041] Furthermore, there is a drain opening 16 on the underside of the test container 1 in order to be able to drain media (e.g. paint, stylistic agents, compressed air) during the acoustic functional test.

[0042] The test container 1 according to the invention is characterized in that it is not stationary, but movable, namely on a transport sled 17 (skid), as is otherwise used in painting plants for conveying the motor vehicle body components to be painted.

[0043] For this purpose, the transport carriage 17 can be moved on guide rails 18, 19 along the paint line.

[0044] Furthermore, it should be mentioned that the test container 1 is mounted on the transport carriage 17 by means of a lifting device 20. The lifting device 20 enables the test container 1 to be raised relative to the transport carriage 17 so that the test container 1 can be positioned at a suitable height for carrying out the acoustic functional test.

[0045] Figure 4 Figure 1 shows a side view of the transport carriage 17 with the test container 1. This illustration also shows that three further test containers 21-23 are arranged behind test container 1, opposite to the conveying direction. Test containers 1, 21, 22, and 23 differ in size, with each individual test container 1, 21, 22, and 23 being adapted to a specific type of application device to be tested.

[0046] The Figures 5A and 5B Figure 24 shows a painting system according to the invention for painting motor vehicle body components.

[0047] Figure 5A This shows the normal painting operation, in which the motor vehicle body components 24 are arranged in a painting booth 25 and are painted by the rotary atomizer 2.

[0048] During this painting operation, the transport carriage 17 with the test containers 1, 21, 22, 23 is located outside the paint booth 25. This is advantageous because the transport carriage 17 with the test containers 1, 22, 23, 24 is not contaminated by paint residue. It is also advantageous because the painting operation is not obstructed by the transport carriage 17 with the test containers 1, 22, 23, 24.

[0049] Figure 5BIn contrast, the acoustic functional test of the rotary atomizer 2 is shown. For this purpose, the transport carriage 17 with the test containers 1, 21, 22, 23 has been moved into the paint booth 25, so that the paint robot 3 can insert the rotary atomizer 2 into the associated test container 1.

[0050] The flowchart will now be presented according to Figure 5 written, which clarifies the test method according to the invention.

[0051] In the first step S1, a normal painting operation takes place, as is done in Figure 5A The transport carriage 17 with the test containers 1, 21, 22, 23 is then located outside the paint booth 25, as described above.

[0052] In step S2, it is then checked whether to switch to a test mode in which an acoustic functional test of the rotary atomizer 2 is to be carried out.

[0053] If this is the case, the transport carriage 17 with the test containers 1, 21, 22, 23 is moved into the paint booth 25 in one step S3.

[0054] In step S4, the interfering ambient noise is measured by the reference sensors 13 and 14. The insertion opening 4 is still open at this stage, allowing the reference sensors 13 and 14 to measure the ambient noise through the open insertion opening 4.

[0055] In step S5, the rotary atomizer 2 is then inserted into the associated test container 1.

[0056] Subsequently, in step S6, the rotary atomizer 2 goes through a test program within the test container 1.

[0057] In step S7, the sound emissions of the rotary atomizer 2 are measured by the sound sensors 8-11.

[0058] In step S8, the disturbing ambient noise is then subtracted from the measured sound emissions of the rotary atomizer 2.

[0059] In step S9, the sound emissions of the rotary atomizer 2 are then evaluated as part of the functional test.

[0060] In step S10, it is then checked whether the system switches back to normal painting operation.

[0061] If this is the case, the rotary atomizer 2 is first moved out of the associated test container 1 in step S11.

[0062] In the next step S12, the transport carriage 17 with the test containers 1, 21, 22, 23 is then moved out of the paint booth 25.

[0063] In the final step S13, the painting operation is then resumed, as described in Figure 5A is shown schematically. Reference symbol list

[0064] 1 Test container for acoustic functional testing 2 Rotary atomizer 3 Painting robot 4 Inlet opening of the test container 5, 6 Opening flaps of the test container 7 Sealing lip at the inlet opening of the test container 8-11 Sound sensors for measuring the sound emissions of the atomizer 12 Ventilation base of the test container 13, 14 Reference sensors for measuring ambient noise 15 Soundproofing lining in the test container 16 Outlet opening of the test container 17 Transport carriage (skid) 18, 19 Travel rails 20 Lifting device 21-23 Test container 24 Automotive body component 25 Paint booth

Claims

1. Test device for an acoustic functional test of an application device (2), the application device (2) being used in a coating installation for coating components (24), with a) at least one test container (1; 21-23) for receiving the application device (2) to be tested during the acoustic functional test, wherein the test container (1; 21-23) comprises an insertion opening (4) in order to be able to insert the application device (2) to be tested through the insertion opening (4) into the test container (1; 21-23), and b) a coating booth (25) for coating the components (24), characterized in c) that the test container (1; 21-23) is movably arranged in the coating installation, d) that the test container (1; 21-23) can be moved into the coating booth (25) for a functional test of the application device (2) to be tested, e) that the test container (1; 21-23) can be moved out of the coating booth (25) for a coating of the components (24), f) that the test container (1; 21-23) comprises a seal (7) for sealing the insertion opening (4) when the application device (2) is inserted into the test container (1; 21-23), and g) that the seal (7) comprises an annular circumferential sealing lip (7) on the circumferential edge of the insertion opening (4), the sealing lip (7) bearing sealingly against the application device (2) when the application device (2) is inserted into the test container (1; 21-23).

2. Test device according to claim 1, characterized in, a) that, for conveying the test container (1; 21-23) through the coating installation, a transport carriage (17) is provided which can be moved through the coating installation, in particular along a coating line, and b) that the test container (1; 21-23) is attached to the transport carriage (17) so that the test container (1; 21-23) moves with the transport carriage (17).

3. Test device according to claim 2, characterized by a lifting device for lifting the test container (1; 21-23) from the transport carriage (17).

4. Test device according to one of the claims 2 or 3, characterized in, a) that a plurality of test containers (1; 21-23) are attached to the transport carriage (17), in particular a1) one behind the other in the conveying direction or a2) next to each other with respect to the conveying direction, b) that the various test containers (1; 21-23) are preferably adapted to different types of application devices, in particular b1) with different sizes of the test containers (1; 21-23), b2) with differently sized insertion openings (4) of the test containers (1; 21-23), b3) with differently shaped insertion openings (4) of the test containers (1; 21-23).

5. Test device according to one of the preceding claims, characterized in, a) that the insertion opening (4) is arranged on the upper side of the test container (1; 21-23), so that the application device (2) to be tested can be inserted into the test container (1; 21-23) from above, b) that the test container (1; 21-23) has at least one movable opening flap (5, 6), which is movable between a closed position and an open position, c) that the test container (1; 21-23) has a ventilation bottom (12) which is permeable to air and preferably runs transversely to the insertion direction, in particular horizontally, d) that the test container (1; 21-23) has a discharge opening (16) on its underside in order to discharge coating agent residues, rinsing agent residues and / or compressed air from the test container (1; 21-23).

6. Test device according to one of the preceding claims, characterized in, a) that the test container (1; 21-23) has a sound-absorbing sound insulation lining (15) on its inside, b) that the sound-absorbing lining (15) is preferably replaceable.

7. Test device according to one of the preceding claims, characterized in, a) that the test container (1; 21-23) has at least one sound sensor (8-11) for detecting sound emissions from the application device (2) to be tested in the test container (1; 21-23), b) that the sound sensor (8-11) is preferably directed into the interior of the test container (1; 21-23), c) that several sound sensors (8-11) are arranged in the test container (1; 21-23), preferably distributed over the circumference, d) that a plurality of sound sensors (8-11) are preferably arranged one above the other in a plurality of planes in the test container (1; 21-23).

8. Test device according to one of the preceding claims, characterized in, a) that the test container (1; 21-23) has at least one reference sensor (13, 14) in order to detect ambient noise and to be able to calculate it out of the sound emissions measured by the sound sensor, b) that the reference sensor (13, 14) preferably has a main measuring direction which is directed outwards through the insertion opening (4) of the test container (1; 21-23) in order to detect the ambient noises, c) that the reference sensor (13, 14) is preferably arranged below the ventilation bottom (12), d) that a plurality of reference sensors (13, 14) are preferably arranged in the test container (1; 21-23) for measuring the ambient noises, which reference sensors (13, 14) are preferably oriented differently.

9. Test device according to one of the preceding claims, characterized by an evaluation unit which is connected to the sound sensor (8-11) and preferably also to the reference sensor (13, 14) and carries out the functional test by evaluating the sound emissions of the application device (2).

10. Coating installation for coating components (24) with a test device according to one of claims 1 to 9.

11. Test method for an acoustic functional test of an application device (2), the application device (2) being used in a coating installation for coating components (24), with the following steps: a) Coating the components (24) to be coated in a coating booth (25), b) introducing the application device (2) to be tested into a test container (1; 21-23), in particular by means of a painting robot (3), wherein the test container (1; 21-23) comprises an insertion opening (4) in order to be able to insert the application device (2) to be tested through the insertion opening (4) into the test container (1; 21-23), c) measuring sound emissions of the application device (2) to be tested inside the test container (1; 21-23) by means of at least one sound sensor (8-11), and d) evaluating the measured sound emissions of the application device (2) to be tested for the functional test of the application device (2), characterized in e) that the test container (1; 21-23) is arranged movably in the coating installation,, f) that the test container (1; 21-23) is moved into the coating booth (25) for a functional test of the application device (2) to be tested, g) that the test container (1; 21-23) is moved out of the coating booth (25) for a coating of the components (24), h) that the test container (1; 21-23) comprises a seal (7) for sealing the insertion opening (4) when the application device (2) is inserted into the test container (1; 21-23), and i) that the seal (7) comprises an annular circumferential sealing lip (7) on the circumferential edge of the insertion opening (4), the sealing lip (7) bearing sealingly against the application device (2) when the application device (2) is inserted into the test container (1; 21-23).

12. Test method according to claim 11, characterized by the following steps: a) measuring ambient noise by at least one reference sensor (13, 14), b) preferably extracting the ambient noise measured by the reference sensor (13, 14) from the sound emissions of the application device (2) measured by the sound sensor (8-11).