Ceramic-Coated Air Bearing Shaft to Reduce Voltage Flashovers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rotary atomizers experience frequent voltage flashovers between the bearing parts of the air bearing, leading to surface defects and reduced operational lifespan, necessitating premature maintenance or replacement.
Innovation Solution
The air bearing comprises a bearing bush made of graphite or bronze and a shaft element with bearing sections made of materials like titanium carbonitride TiCN, which define a bearing surface, reducing flashovers and extending the service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air bearing components are used, then the device can operate, but voltage flashovers occur frequently causing surface defects and reduced service life
Solution Approach 1:
The shaft element employs a composite structure with a metallic base material and a ceramic coating layer. This composite design combines the mechanical strength of metal with the electrical insulation and surface hardness of ceramic, preventing voltage flashovers while maintaining structural integrity and reducing surface defects.
Solution Approach 2:
The invention changes the material parameters of the bearing surfaces by applying ceramic coatings with specific electrical insulation properties and surface characteristics. This parameter change reduces the frequency of voltage flashovers and minimizes surface defects, thereby extending service life.
2Ease of manufacture
If the shaft element and bearing bushing materials are conventional, then manufacturing is simple, but surface roughening occurs due to sputtering
Solution Approach 1:
The ceramic-coated shaft element combines conventional metallic base materials with advanced ceramic coating materials. This composite approach maintains ease of manufacturing the base component while the ceramic coating layer protects against surface roughening from sputtering, preserving surface quality.
Solution Approach 2:
The ceramic coating layer acts as a sacrificial protective layer that can be applied economically to the shaft element. While the coating itself may wear over time, it protects the more expensive shaft element, and can be reapplied or the component replaced more easily than redesigning the entire bearing system.
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 solution significantly prolongs the operational life of the air bearing and rotary atomizer components by minimizing surface defects and maintaining performance.
Implementation Method 1
the bearing bushing is made of graphite or bronze or sintered bronze or sintered steel at least on its inner surface
Implementation Method 2
an air bearing comprising as the first bearing part a bearing bushing and as the second bearing part a shaft element
Implementation Method 3
Due to centrifugal forces acting on it, the coating material is forced outwards as a film until it reaches a radially outer edge of the plate
Data Source
AI summary
A shaft element (40) is specified, which is a bearing part of an air bearing (36), the shaft element (40) having at least one bearing section (52), with which the shaft element (40) is mounted in a bearing bushing (38) of the air bearing (36 ) is feasible. The shaft member (40) has a shaft portion (50) made of a first material and defines a bearing surface (58) made of a second material at least in the bearing portion (52). An air bearing (36), in particular an air bearing for a rotary atomizer (12), is also specified, which comprises a bearing bush (38) as the first bearing part and such a shaft element (40) as the second bearing part. A rotary atomizer (12) for applying a coating material to an object comprises a bell plate (16) rotatable about an axis of rotation (18), a drive unit (26) for the bell plate (16) and such an air bearing (36).