Color manifold and valve assembly

Abstract

To limit paint waste.SOLUTION: A paint manifold includes: a body having a fluid passage extending therethrough; a first valve having a valve tip positioned proximately to the fluid passage; a second valve having a valve tip positioned proximately to the fluid passage; and a third valve having a valve tip positioned proximately to the fluid passage. The manifold also includes a paint discharge passage extending through the body and coupled to the first valve, a paint return passage extending through the body and coupled to the first valve, a paint discharge passage extending through the body and coupled to the second valve, a paint return passage extending through the body and coupled to the second valve, a paint discharge passage extending through the body and coupled to the third valve, and a paint return passage extending through the body and coupled to the third valve.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of the filing date of U.S. Provisional Application No. 63 / 583,100, entitled “COLOR MANIFOLD AND VALVE ASSEMBLY,” filed September 15, 2023, the entire text of which is expressly incorporated by reference herein.

[0002] The present disclosure relates generally to fluid manifolds, and more specifically to a paint manifold for a robotic paint dispensing system having three valves positioned on a common plane with each valve tip positioned proximate a central paint passage. [Background technology]

[0003] Robots are known to perform a number of tasks, including painting objects such as vehicle bodies. A typical robotic paint station, for example for painting the exterior of a vehicle body, in both continuous transport and stationary systems, includes a spray booth, multiple paint robots, and opener / closer robots arranged around the perimeter. Such robots may be mounted on the floor, walls, ceiling, or side rails. The paint robots carry either spray guns or rotary applicators for directing atomized paint onto the vehicle body.

[0004] A typical paint delivery system for a painting robot will include a paint manifold with multiple valves that are controlled to selectively provide different colors of paint to a fluid manifold that meters and controls the flow of paint to the paint applicators. Because vehicle paint is expensive, efforts are made to reduce paint waste. One method of reducing paint waste is to reduce the amount of paint in the manifold at the end of a painting operation. The paint is generally drained into a paint dump to clean the manifold for the next painting operation. The distance that paint travels through hoses and passageways in such a manifold varies by design. One method of reducing the amount of paint in the manifold at the end of a painting operation is to reduce the distance that 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 that includes a body having a fluid passage extending 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 stem seal having a sealing surface that seals against the body and a valve seat having a semispherical surface. The manifold also includes a fluid supply passage extending through the body and coupled to the first valve, a fluid return passage extending through the body and coupled to the first valve, a fluid supply passage extending through the body and coupled to the second valve, a fluid return passage extending through the body and coupled to the second valve, a fluid supply passage extending through the body and coupled to the third valve, and a fluid return passage extending through the body and coupled to the third valve.

[0006] Additional features of the present disclosure will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is an isometric view of a painting robot. [Diagram 2] FIG. 2 is a schematic diagram of a paint dispensing system including a paint manifold and a paint canister that can be used with the painting robot shown in FIG. [Diagram 3] FIG. 3 is a schematic diagram of another paint delivery system including a paint manifold and a pump manifold that can be used with the painting robot shown in FIG. [Figure 4] FIG. 4 is a front isometric view of a paint manifold that can be used as the paint manifold in the paint delivery system shown in FIGS. [Diagram 5] FIG. 5 is a rear isometric view of the paint manifold shown in FIG. [Figure 6] FIG. 6 is a front view of the paint manifold shown in FIG. [Figure 7] FIG. 7 is a rear view of the paint manifold shown in FIG. [Figure 8] FIG. 8 is a side view of the paint manifold shown in FIG. [Figure 9] FIG. 9 is a top view of the paint manifold shown in FIG. [Figure 10] FIG. 10 is a rear view of the paint manifold shown in FIG. 4 with a transparent block showing the internal fluid passages. [Figure 11] FIG. 11 is an isometric view of the paint manifold showing the valve sockets positioned therein. [Figure 12] FIG. 12 is an exploded front view of the paint manifold showing a cross section of one of the valves positioned therein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The following discussion of embodiments of the present disclosure relating to a paint manifold for a robotic paint dispensing system having three valves positioned on a common plane with the tips of each valve positioned proximate a central fluid passage is exemplary in nature and is not intended to limit the invention or its applications or uses. For example, although the discussion herein is specific to a paint dispensing system for a paint robot that paints vehicle parts, the paint dispensing system is applicable for dispensing other coatings or fluids by other devices for other applications.

[0009] 1 is an isometric view of a paint robot 10 mounted to a fixed base mounting stand 12, where robot 10 is intended to represent any paint robot suitable for the purposes discussed herein. A turret or robot base 14 is rotatably mounted to the mounting stand 12. An inner arm 18 is rotatably coupled to the base 14 by a joint 20, an outer arm 22 is rotatably coupled to the inner arm 18 by a joint 24, and a wrist member 26 is rotatably coupled to the outer arm 22 by a joint 28. An applicator 30 is fixed to the wrist member 26 at an angle optimized for the painting application and is shown ejecting a paint spray 32 from the applicator 30.

[0010] FIG. 2 is a schematic block diagram of a paint dispensing system 40 that can be used with the paint robot 10 shown in FIG. 1. Although the discussion herein is specific to a paint robot for painting, for example, an automobile body, it is noted that the paint dispensing system 40 can also be used to apply other coatings or fluids by other devices for other applications. The system 40 includes an applicator 42, such as a rotary sprayer having a trigger valve 44 connected to a paint delivery line 46, where 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 the end effector of the robot 10. The system 40 also includes a paint manifold 50 having a number of color valves 52 that are selectively opened to obtain paint from a number of paint sources 54 and provide 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 to the isolation line 58. The paint manifold 50 also includes a dump valve 64 for dumping solvent and air from the system 40 to an exhaust 66. The paint manifold 50 further includes a vacuum valve 68 coupled to a vacuum source for evacuating air from the passages in the system 40 before it is filled with paint.

[0011] The system 40 further includes a canister manifold 70 having a paint canister 72 attached thereto, the canister 72 having a chamber 74 therein. The canister 72 also includes a piston 76 defining a paint volume 78 between the canister 72 and the chamber 74. The paint volume holds a predetermined amount of paint when the canister 72 is filled with paint, the piston 76 being pneumatically actuated, fluidically actuated, or the like. A paint input line 80 allows paint to be charged to the volume 78 from the isolation line 58 via a paint input valve 82, and a paint output line 84 allows paint to be dispensed from the paint volume 78 via a paint outlet valve 86 and into the paint delivery line 46 by movement of 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 flushed and dried in a manner well known to those skilled in the art.

[0012] System 40 also includes a flush manifold 92 having valves 94, 96 and 98 coupled by isolation lines 100 to valves 88 and 90 of manifold 70. A solvent source 102 provides solvent to manifold 92 via valve 98. An air source 104 provides dry air to manifold 92 via valve 94. During a painting operation, paint canister 72 and applicator 44 are at high voltage and paint manifold 50 and manifold 92 are grounded by the fluid supply. Therefore, canister 72 must be electrically isolated from paint manifold 50 and flush manifold 92 to prevent ground faults. Therefore, isolation lines 58 and 100 are empty and clean during a painting operation to provide electrical isolation.

[0013] 3 is a schematic diagram of another paint delivery system 110 that can 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. Paint is provided from the pump manifold 116 to an applicator 118 (e.g., applicator 30) on line 180 for distribution onto the parts. The solvent / air manifold 112 receives cleaning solvent from a solvent source 124 and air from an air source 126. Solvent is provided to a solvent valve 130 via a flow controller 132, which is then provided to a control valve 134. A solvent valve 140 allows the solvent to bypass the flow controller 132 and the control valve 134. Air is provided to an air valve 142, and solvent and / or air is provided to a solvent supply valve 144. Paint manifold 114 includes three paint valves 146 that can selectively provide paint to lines 120 and may be a paint manifold, discussed in more detail below. It should be noted that in other embodiments, system 110 may support multiple paint manifolds to provide even more paint colors from even more sources.

[0014] The pump manifold 116 includes a pressure regulator 150 for regulating the flow of fluid on the lines 120, an inlet sensor 152 for measuring the fluid pressure on the lines 120 at the inlet of the pump manifold 116, and an outlet sensor 154 for measuring the fluid pressure on the lines 120 at the outlet of the pump manifold 116. The pump manifold 116 also includes a pump 156 for pumping fluid through the system 110. A dump valve 158 on the inlet side of the pump 156 allows solvent or air to be drained from the system 110, and a dump valve 160 on the outlet side of the pump 156 allows solvent or air to be drained 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 paint through a paint discharge valve 170 and a trigger valve 172. Valve 144 on line 182 provides air and solvent to applicator flush valves 174 , 176 and 178 .

[0015] As will be appreciated by those skilled in the art, the various valves, pumps, flow controllers and other equipment in system 110 are appropriately controlled to distribute paint from one of the color sources through one of the color valves 146, the pump manifold 116 on line 120, line 180 and valves 170 and 172, and out of applicator 118.

[0016] FIG. 4 is a front isometric view, FIG. 5 is a rear isometric view, FIG. 6 is a front view, FIG. 7 is a rear view, FIG. 8 is a side view, and FIG. 9 is a top view of a paint manifold 200 that may be part of the paint manifold 50 of the paint dispensing system 40 shown in FIG. 2 and the paint manifold 114 of the paint dispensing system 110 shown in FIG. 3. The paint manifold 200 comprises a specially shaped block 202 made, for example, from acetal copolymer, with various faces and features as shown. It should be noted that the shape of the block of the manifold 200 is a non-limiting example in that other shapes, such as a semicircular shape, are also possible. The block 202 comprises a front side 204, a rear side 206, a left side 208, a right side 210, and an upper side 212. In one non-limiting embodiment, the depth between the front side 204 and the rear side 206 of the block 202 is 18-58 mm. The front side 204 includes recesses 220 and 222 that open to the top side 212 with relief steps 224 and 226, respectively. The top side 212 includes a notch 232 and the block 202 includes a V-shaped cutout 234 at its bottom. A central passage 236 extends through the block 202 from the front side 204 to the rear side 206, and a pair of alignment bosses 244 and 246 extend from the rear side 206 of the block 202.

[0017] FIG. 10 is a front view of the paint manifold 200, where the block 202 is shown transparent to show the fluid passages therein. The paint manifold 200 includes a valve 260 extending into the block 202 through the cutout 232 in the top portion 212, a valve 262 extending into the block 202 through the left side portion 208, and a valve 264 extending into the block 202 through the right side portion 210. Here, the ends of the valves 260, 262, and 264 are positioned adjacent to the central passage 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 one another can be any angle suitable for the purposes discussed herein, for example, in the range of 85° to 125°. Valve 260 has an air fitting 270 coupled to the end of valve 260 opposite the central passage 236, valve 262 has an air fitting 272 coupled to the end of valve 262 opposite the central passage 236, and valve 264 has an air fitting 274 coupled to the end of valve 264 opposite the central passage 236. This configuration of valves 260, 262, and 264 minimizes the distance that paint travels through central passage 236 when a particular valve 260-264 is open, reducing paint waste.

[0018] 11 is an isometric view of block 202 with valves 260, 262, and 264 removed. Block 202 includes a valve socket 266 having configurations and features for receiving valve 260, such that block 202 serves as the valve body for valve 260. Similarly, block 202 includes a valve socket 268 having configurations and features for receiving valve 262, such that block 202 serves as the valve body for valve 262. Similarly, block 202 includes a valve socket 276 having configurations and features for receiving valve 264, such that block 202 serves as the valve body for valve 264.

[0019] Each valve 260, 262, and 264 allows the flow of paint from a different paint source to the central passageway 236. The supply passageway 280 is coupled to the valve 260 and a supply fitting socket 316 in the block 202 through the top section 212, and the return passageway 284 is coupled to the valve 260 and a return fitting socket 298 in the block 202 through the top section 212. Here, the paint fitting 320 is inserted into the socket 316, and the paint fitting 302 is inserted into the socket 298. When the valve 260 is closed, paint from the paint source can circulate through the supply passageway 280, through the chamber in the valve 260, and back through the return passageway 284 to the paint source. When the valve 260 is open, paint from the supply passageway 280 is directed to the central passageway 236.

[0020] Similarly, supply passage 292 is coupled to valve 262 and a supply fitting socket 294 in block 202 through top portion 212, and return passage 296 is coupled to valve 262 and a return fitting socket 286 in block 202 through top portion 212. Now, paint fitting 300 is inserted into socket 294 and paint fitting 290 is inserted into socket 286. When valve 262 is closed, paint from the paint source can circulate through supply passage 292, through a chamber in valve 262, and back through return passage 296 to the paint source. When valve 262 is open, paint from supply passage 292 is directed into central passage 236.

[0021] Similarly, supply passage 310 is coupled to valve 264 and a supply fitting socket 312 in block 202 through top section 212, and return passage 314 is coupled to valve 264 and a return fitting socket 282 in block 202 through top section 212. Paint fitting 318 is now inserted into socket 312, and paint fitting 288 is inserted into socket 282. When valve 264 is closed, paint from the paint source can circulate through supply passage 310, through a chamber in valve 264, and back through return passage 314 to the paint source. When valve 264 is open, paint from supply passage 310 is directed into central passage 236. Note that boss 328 is required in the layout of sockets 282, 312 and 316, and boss 338 is required in the layout of sockets 286, 294 and 298, to allow multiple manifolds to be stacked back-to-back, because recesses 220 and 222 act as relief cutouts for the bosses of adjacent manifolds.

[0022] Weep passage 322 can be used to provide a visual indication of whether the seal on the fluid side of valve 260 is leaking, weep passage 324 can be used to provide a visual indication of whether the seal on the fluid side of valve 262 is leaking, and weep passage 326 can be used to provide a visual indication of whether the seal on the fluid side of valve 264 is leaking.

[0023] 12 is an exploded front view of the paint manifold 200 showing a cross-sectional view of the valve 260 positioned in the socket 266, although it should be understood that the valves 262 and 264 are identical to the valve 260. The valve 260 includes an air side 330 having an air chamber 332 for receiving pilot air, and a fluid side 334 having a paint chamber 336 for receiving paint from the supply passage 280. The valve 260 further includes a valve stem 340 extending along the length of the valve 260 and coupled to a valve tip 374 that seats on a valve seat 372 having a semi-spherical surface. A pilot passage 342 extends through the valve stem 340 to provide pilot 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 pilot side seal 362 seal the air chamber 332, and a fluid side rod seal 370 seals the paint chamber 336. A seal retainer 368 holds the pilot side seal 362 in place and prevents pilot air from entering the paint chamber 336. A bleed passage 366 is in fluid communication with the bleed passage 322.

[0024] When pilot air is provided to the pilot passage 342, the air chamber 332 is pressurized, causing the valve stem 340 to move upward against the bias of the spring 354, causing the valve tip 374 to separate from the valve seat 372 and allowing paint to be dispensed from the paint chamber 336 into the central passage 236. When the pilot air is removed, the spring 354 forces the valve stem 340 downward, causing the valve tip 374 to reseat on the valve seat 372 and close the valve 260.

[0025] In known valve designs, the fluid side rod seal seals against the valve stem at the seal inner diameter and against the valve body at the seal outer diameter. However, in manifold 200, fluid side rod seal 370 seals directly against block 202 at the seal outer diameter. Because block 202 serves as the valve body for valves 260, 262, and 264, paint manifold 200 has a more compact design, which reduces costs by eliminating the need for external O-ring seals required in known valve designs. Additionally, removing the valve body allows supply passages 280, 292, and 310 and return passages 284, 296, and 314 to be angled relative to their respective valves 260, 262, and 264, which also aids in the compact design of paint manifold 200. Seal retainer 368 retains pilot seal 362, allowing a common dynamic seal to be used. Seal retainer 368 also functions to create a seal with block 202 without the need for an elastomeric seal. The valve seat 372 can minimize the size of the seat 372 around the valve tip 374 to allow for closer spacing between the valves 260, 262, and 264. This is achieved by moving the retention feature of the seat 372 away from the valve tip 374. This closer spacing is made possible by the hemispherical profile of the seat 372. In another embodiment that can provide such closer spacing, the seat 372 has a generally conical profile. In yet another embodiment that can provide such closer spacing, a one-piece structure can be provided where the seats 372 of the valves 260, 262, and 264 are combined into a single component. The design of the valve stem 340 allows for the air fitting 270 to be directly connected to the stem 340.

[0026] The foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure, and it will be readily apparent to those skilled in the art from such discussion, the accompanying drawings and claims that various changes, modifications, and variations can be made without departing from the spirit and scope of the present disclosure, as defined in the following claims.

Claims

1. 1. A fluid manifold comprising: a body having a fluid passage extending therethrough; a first valve extending into the body and having a valve tip positioned proximate to the fluid passage; a second valve extending into the body and having a valve tip positioned proximate to the fluid passage; and a third valve extending into the body and having a valve tip positioned proximate to the fluid passage, each valve including a stem seal having a sealing surface that seals against the body.

2. 2. The manifold of claim 1, wherein the body is a block having a front side, a rear side, a left side, a right side and a top side, and the fluid passage extends through the block between the front side and the rear side.

3. 3. The manifold of claim 2, wherein the first valve extends into the block through the top side, the second valve extends into the block through the right side, and the third valve extends into the block through the left side.

4. 3. The manifold of claim 2, wherein the thickness of said block between said front and rear sides is in the range of 18-58 mm.

5. 2. The manifold of claim 1, wherein the lengths of each of the first, second and third valves are positioned along a common plane.

6. 6. The manifold of claim 5, wherein the first, second and third valves are oriented at an angle between 85° and 125° relative to one another.

7. a first fluid supply passage extending through the body and coupled to the first valve; a first fluid return passage extending through the body and coupled to the first valve; a second fluid supply passage extending through the body and coupled to the second valve; a second fluid return passage extending through the body and coupled to the second valve; a third fluid supply passage extending through the body and coupled to the third valve; 2. The manifold of claim 1, further comprising a third fluid return passage extending through said body and coupled to said third valve.

8. 10. The manifold of claim 1, wherein each valve comprises an air chamber and a fluid chamber, the air chamber being pressurized with air to actuate the valve.

9. 9. The manifold of claim 8, wherein each valve includes a pilot seal sealing a pilot air chamber and a seal retainer holding the pilot seal in place to prevent air from entering the fluid chamber.

10. The manifold of claim 1 , wherein each valve includes a valve seat having a hemispherical surface.

11. The manifold of claim 1 , wherein each valve includes an exudate passage in fluid communication with an exudate fluid passage extending through the body.

12. 10. The manifold of claim 1, wherein the manifold is part of a paint dispensing system and the fluid is paint.

13. The manifold of claim 12 , wherein the paint dispensing system is part of a painting robot.

14. 1. A paint manifold that is part of a paint dispensing system of a painting robot, the manifold comprising: a body having a front side, a rear side, a left side, a right side and a top side and a fluid passageway extending through the body between the front side and the rear side; a first valve extending into the body and having a valve tip positioned proximate to the fluid passage, the first valve extending into the body through the upper portion; a second valve extending into the body and having a valve tip positioned proximate to the fluid passage, 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 to the fluid passage, the third valve extending into the body through the left side, the first, second and third valves each having a length positioned along a common plane, each valve including a stem seal having a sealing surface that seals against the body and a valve seat having a hemispherical surface.

15. 15. The manifold of claim 14, wherein the body has a thickness between the front and rear sides in the range of 18-58 mm.

16. The manifold of claim 14, wherein the first, second and third valves are oriented at an angle of between 85° and 125° relative to one another.

17. a first fluid supply passage extending through the body and coupled to the first valve; a first fluid return passage extending through the body and coupled to the first valve; a second fluid supply passage extending through the body and coupled to the second valve; a second fluid return passage extending through the body and coupled to the second valve; a third fluid supply passage extending through the body and coupled to the third valve; The manifold of claim 14 further comprising a third fluid return passage extending through the body and coupled to the third valve.

18. 1. A paint manifold comprising: a body having a fluid passage extending therethrough; a first valve extending into the body and having a valve tip positioned proximate to the fluid passage; a second valve extending into the body and having a valve tip positioned proximate to the fluid passage; a third valve extending into the body and having a valve tip positioned proximate to the fluid passage, each valve including a stem seal having a sealing surface that seals against the body and a valve seat having a hemispherical surface; a first fluid supply passage extending through the body and coupled to the first valve; a first fluid return passage extending through the body and coupled to the first valve; a second fluid supply passage extending through the body and coupled to the second valve; a second fluid return passage extending through the body and coupled to the second valve; a third fluid supply passage extending through the body and coupled to the third valve; a third fluid return passage extending through the body and coupled to the third valve.

19. 20. The manifold of claim 18, wherein the body is a block having a front side, a rear side, a left side, a right side and a top side, the fluid passage extending through the block between the front side and the rear side, the first valve extending into the block through the top side, the second valve extending into the block through the right side and the third valve extending into the block through the left side.

20. The manifold of claim 18 , wherein each valve includes an exudate passage in fluid communication with an exudate fluid passage extending through the body.

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