Arc Wire Spraying Equipment Rotating Airflow for Uniform Coating
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Solution Overview
Problem
Existing arc wire spraying technologies face challenges in achieving uniform coating thickness on the inner surface of cylindrical cavities, leading to issues like non-uniform heat conduction, pore formation, coating peeling, and increased operational costs due to the complex and heavy structure of the equipment, which results in partial overheating, corrosion, and reduced service life of internal combustion engines.
Innovation Solution
The method involves using an arc wire spraying equipment with a wire conveying device and an airflow applying device, where the airflow is rotated around the wire conveying device, allowing for variable adjustment of parameters such as rotating speed, airflow rate, and current along the spraying direction to ensure uniform coating thickness, eliminating the need for the wire conveying device to rotate and reducing the frequency of wire winch replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire conveying device rotates together with the airflow applying device to spray the inner surface of a cylindrical cavity, then the coating can be formed on the inner circumference, but the wire conveying device becomes complex and heavy, requiring a wire winch that needs frequent replacement
Solution Approach 1:
The system is divided into two independent parts: the wire conveying device remains stationary while only the airflow applying device rotates. This segmentation allows the wire feeding mechanism to be simplified without affecting the coating capability, as the rotating airflow device can still deliver uniform coating coverage.
Solution Approach 2:
Instead of rotating the wire conveying device as in conventional methods, this invention inverts the approach by keeping the wire conveying device stationary and rotating only the airflow applying device. This inversion simplifies the wire feeding mechanism while maintaining coating effectiveness through the rotating airflow that distributes molten metal uniformly.
2Device complexity
If the wire conveying device does not rotate with the airflow applying device, then the structure is simplified, but the coating becomes non-uniform with elliptic inner edge and varying thickness
Solution Approach 1:
The airflow applying device is made dynamic by enabling it to rotate around the stationary wire conveying device. This rotation creates dynamic airflow patterns that distribute the molten metal particles uniformly across the cylindrical inner surface, compensating for the lack of wire device rotation and ensuring uniform coating thickness.
Solution Approach 2:
The invention uses compressed air (pneumatics) as the primary mechanism to achieve uniform coating. The rotating airflow applying device directs high-velocity air streams that atomize and distribute the molten metal particles uniformly, replacing the need for mechanical rotation of the wire conveying device and achieving both structural simplification and coating uniformity.
3Ease of operation
If the coating thickness is non-uniform with thicker and thinner positions, then the equipment operation is simpler, but the engine experiences overheating, pore formation, and reduced service life
Solution Approach 1:
The system incorporates feedback control where the rotation of the airflow applying device and the parameters of the arc wire spraying process are adjusted to achieve uniform coating thickness. This feedback mechanism ensures that the coating meets precise thickness requirements, preventing the reliability issues of overheating and pore formation while maintaining operational simplicity.
Solution Approach 2:
The invention optimizes process parameters including airflow rate, wire feed speed, and arc current to achieve uniform coating thickness. By carefully controlling these parameters during the spraying process, the system produces consistent coating quality that prevents engine reliability issues while keeping the operation simple and efficient.
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
This approach results in a significantly reduced diameter difference between the thinnest and thickest coating positions, preventing overheating, pore formation, and peeling, thereby extending the service life of the engine and reducing manufacturing and honing tool costs by ensuring uniform coating tension and heat conduction.
Implementation Method 1
a burning rod for arc spraying and a wire conveying device for conveying coat wire, the burning rod melts a wire material by means of arc
Implementation Method 2
atomizing the melted metal with compressed air and spraying the atomized metal particles
Implementation Method 3
applying airflow to the arc in the direction approximately transverse to the longitudinal direction of the wire conveying device by means of an airflow applying device so as to spray the melted wire material
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~5a
AI summary
An arc wire spraying method comprising the following steps: conveying at least two wires out of respective lance nozzles (4) of a wire conveying device (2) by means of the wire conveying device (2), applying current to the at least two wires to form an arc for melting the ends of the at least two wires, and applying airflow (9) to the arc in the direction approximately transverse to the longitudinal direction (z) of the wire conveying device (2) by means of an airflow applying device (3) so as to spray the melted wire material toward a surface (5) to be sprayed, wherein the airflow applying device (3) rotationally applies the airflow (9) around the longitudinal direction (z) of the wire conveying device (2), wherein parameters for spraying are variably adjusted along the rotating direction of the airflow applying device (3). An arc wire spraying equipment and an arc wire sprayed product are also disclosed.