3D Part Cleaning via Dynamic Rotation and Scanning
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Solution Overview
Problem
Conventional spray treatment systems for 3D-shaped hot-dip galvanized steel surfaces face challenges in achieving uniform cleaning due to uneven distribution of cleaning jets, which results in variable pressure and angle of impact on different surface portions, leading to inconsistent cleaning effects.
Innovation Solution
A spray treatment system incorporating a conveyor mechanism, 3D scanner, and part rotating mechanism, where the 3D scanner generates data on the part's shape and size, allowing the processor to adjust the part's orientation and the spray nozzles' operation to ensure consistent distance and pressure of cleaning jets on all surface portions, thereby overcoming the limitations of conventional systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray treatment systems are used on 3D-shaped parts, then the system structure is simple, but the cleaning uniformity deteriorates due to uneven jet distribution and variable impact pressure on different surface portions
Solution Approach 1:
The system dynamically adjusts the orientation of the part during cleaning operations. The part rotating mechanism allows the part to be rotated to different angles and positions, enabling the cleaning jets to maintain consistent impact pressure and angle across all surface portions, thereby resolving the cleaning uniformity issue without requiring complex nozzle arrangements
Solution Approach 2:
The 3D scanning is performed before the cleaning operation to capture the exact geometry and surface characteristics of the part. This preliminary action provides data that is used to pre-calculate the optimal rotation angles and positions, allowing the system to achieve uniform cleaning through coordinated rotation and spraying rather than through complex real-time adjustments
2Manufacturing precision
If the part is moved along a cleaning path with fixed nozzles, then the conveyor operation is simple, but the cleaning effectiveness deteriorates on shadowed or hard-to-reach surface portions
Solution Approach 1:
Instead of moving the nozzles dynamically to track complex part geometries, the system dynamically rotates the part itself during conveyance. This approach ensures that all surface portions, including shadowed and hard-to-reach areas, are exposed to the cleaning jets at appropriate angles while maintaining simple fixed nozzle positions and straightforward conveyor operation
Solution Approach 2:
The system adds the dimension of part rotation about its longitudinal axis to the conventional linear conveyance motion. This rotational degree of freedom ensures that all surface portions of 3D-shaped parts are exposed to cleaning jets from multiple angles, eliminating shadowed areas and improving overall cleaning coverage without complicating the conveyor mechanism
3Manufacturing precision
If multiple spray nozzles are positioned along both sides of the cleaning path, then the cleaning coverage is increased, but the pressure distribution and angle of impact become variable across different surface portions
Solution Approach 1:
The system uses dynamic rotation of the part to achieve uniform pressure distribution instead of using complex nozzle positioning systems. By rotating the part to predetermined angles, the fixed nozzle arrangement maintains consistent impact pressure and angle on all exposed surface portions, eliminating the pressure variability problem while keeping the nozzle arrangement relatively simple
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures uniform cleaning by adjusting the relative distance and angle of cleaning jets on 3D-shaped surfaces, ensuring thorough coverage and effective removal of contaminants without overshadowing any surface portions, thus improving the overall cleaning efficacy.
Implementation Method 1
The nozzles are supplied with a cleaning agent, for example a mild acidic solution (e.g. a mixture of 25 parts water to one-part acid) or a mild alkaline solution (e.g. a mixture of ten parts water and one part alkaline cleaner) via supply lines that carry the cleaning agent from a reservoir or supply (not shown) to the nozzles propelled by a pump. The cleaning agent is ejected out of the nozzles towards the surface of the part in form of sprays or jets, hereinafter referred to as the cleaning jets or simply as the jets
Implementation Method 2
The zinc compounds, mostly zinc oxide and zinc hydroxide, must be removed before painting. Partially weathered galvanized steel is the most common galvanized surface condition requiring painting, and also the most difficult to prepare and requiring thorough cleaning of the surface as part of surface preparation for subsequent painting
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention refers to a spray treatment system (1) for cleaning a surface (6) of a 3D part (5). A conveyor mechanism (10) supports and moves the part (5) along a cleaning path (90) having a central axis (95). A plurality (22) of spray nozzles (20) positioned along sides (91,92) of the cleaning path spray a cleaning agent (3) in form of cleaning jets (25) towards the part (5). A 3D scanner (40,40') of the system (1) scans the part (5) to be cleaned and determines a shape and/or a size of the part (5) and generates corresponding data that is received by a processor (50) which then consequently directs a part rotating mechanism (30) to orient the part (5) based on the shape and/or the size of the part (5) such that a surface portion (4,4') of the surface (6) of the part (5) is disposed at a predetermined distance from at least one spray nozzle (20) from the plurality (22) of spray nozzles (20).